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OPERATOR’S MANUAL MODEL 703E PHOTOMETRIC O3 CALIBRATOR © TELEDYNE INSTRUMENTS ADVANCED POLLUTION INSTRUMENTATION DIVISION (TAPI) 9480 CARROLL PARK DRIVE SAN DIEGO, CALIFORNIA 92121-5201 USA Toll-free Phone: Phone: Fax: Email: Website: Copyright 2007 Teledyne Advanced Pollution Instrumentation 800-324-5190 858-657-9800 858-657-9816 [email protected] http://www.teledyne-api.com/ 05743 Rev. C DCN 5521 29 July 2009 THIS PAGE IS INTENTIONALLY LEFT BLANK PRINTED DOCUMENTS ARE UNCONTROLLED. We recommend that this document be read in its entirety before any attempt is made to operate the instrument. DOCUMENTS Document P/N Revision DCN Nomenclature Dated 05743 B 5359 M703, Manual, Instruction - Title 03/20/09 05744 B 5359 M703, Manual, Instruction - Text 03/20/09 05745 C 5359 M703, Appendix A, Menu Tree 03/20/09 05746 B 5359 M703, Appendix B, Spare Parts 03/20/09 05747 B 5359 M703, Appendix C, Repair Form 03/20/09 05748 B 5359 M703, Appendix D, Schematics 03/20/09 05834 F 5359 List, Spare Parts, M703 03/20/09 05863 B 5359 List, Recommended Spares Stocking Levels, M703 03/20/09 05834 J 5480 List, Spare Parts, M703 07/15/09 05863 D 5480 List, Recommended Spares Stocking Levels, M703 07/15/09 THIS PAGE IS INTENTIONALLY LEFT BLANK TELEDYNE API Safety Messages M703E Calibrator Operator’s Manual SAFETY MESSAGES Your safety and the safety of others are very important. We have provided many important safety messages in this manual. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is associated with a safety alert symbol. These symbols are found in the manual and inside the M703E Photometric O3 Calibrator. The definition of these symbols is described below: GENERAL SAFETY HAZARD: Refer to the instructions for details on the specific hazard. CAUTION: Hot Surface Warning. CAUTION: Electrical Shock Hazard. TECHNICIAN SYMBOL: All operations marked with this symbol are to be performed by qualified maintenance personnel only. CAUTION The M703E Photometric O3 Calibrator should only be used for the purpose and in the manner described in this manual. If you use the M703E in a manner other than that for which it was intended, unpredictable behavior could ensue with possible hazardous consequences. NOTE Technical Assistance regarding the use and maintenance of the M703E or any other Teledyne Instruments product can be obtained by: Contacting Teledyne Instruments’ Customer Service Department at 800-324-5190 or Via the internet at http://www.teledyne-api.com/forms 05744 Rev B i TELEDYNE API Safety Messages M703E Dynamic Operator’s Manual USER NOTES: ii 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Table of Contents TABLE OF CONTENTS GENERAL INFORMATION ....................................................................................................... 1 1. INTRODUCTION .................................................................................................................. 3 1.1. M703E calibrator Overview............................................................................................................................3 1.2. Using This Manual .........................................................................................................................................3 2. SPECIFICATIONS, APPROVALS AND WARRANTY ......................................................... 5 2.1. Specifications .................................................................................................................................................5 2.2. CE Mark Compliance .....................................................................................................................................6 2.3. Warranty.........................................................................................................................................................7 3. GETTING STARTED ............................................................................................................ 9 3.1. Unpacking and Initial Setup ...........................................................................................................................9 3.1.1. Model 703E calibrator............................................................................................................................10 3.2. Electrical Connections .................................................................................................................................13 3.2.1. Power Connection..................................................................................................................................13 3.2.2. Analog output TEST CHANNEL Connections .......................................................................................13 3.2.3. Connecting the Status Outputs..............................................................................................................14 3.2.4. Connecting the Control Inputs ...............................................................................................................15 3.2.5. Connecting the Control Outputs ............................................................................................................17 3.2.6. Connecting the Serial Ports ...................................................................................................................18 3.2.7. Connecting to a LAN or the Internet ......................................................................................................18 3.2.8. Connecting to a Multidrop Network........................................................................................................18 3.3. Pnenumatic Connections .............................................................................................................................19 3.3.1. Dry Air In ................................................................................................................................................19 3.3.2. Zero Air In ..............................................................................................................................................19 3.3.3. Output Manifold......................................................................................................................................20 3.3.4. Exhaust ..................................................................................................................................................20 3.3.5. Measuring An External Ozone Source ..................................................................................................20 3.4. Initial Operation ............................................................................................................................................21 3.4.1. START-UP .............................................................................................................................................21 3.4.2. Warm Up................................................................................................................................................22 3.4.3. Warning Messages ................................................................................................................................22 3.4.4. Functional Check ...................................................................................................................................24 3.4.5. Operating Modes for the O3 Generator..................................................................................................25 3.4.5.1. CNST (CONSTANT).......................................................................................................................25 3.4.5.2. REF (REFERENCE).......................................................................................................................25 3.4.5.3. BNCH (BENCH) .............................................................................................................................25 3.4.6. Setting the O3 Generator Mode.............................................................................................................25 3.4.7. Setting the M703E’s output Flow Rate ..................................................................................................26 4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY .................................................. 27 4.1. FAQ’s ...........................................................................................................................................................27 4.2. Glossary .......................................................................................................................................................27 5. OPTIONAL HARDWARE AND SOFTWARE ..................................................................... 29 5.1. Carrying Strap Handle (OPT 29)..................................................................................................................29 5.2. Communication Options...............................................................................................................................30 5.2.1. RS232 Modem Cables (OPTs 60 and 60A) ..........................................................................................30 5.2.2. ETHERNET Cable (OPT 60B)...............................................................................................................30 5.2.3. RS-232 Multidrop (OPT 62) ...................................................................................................................30 5.2.4. Ethernet (OPT 63)..................................................................................................................................31 5.2.5. Ethernet + Multidrop (OPT 64)...............................................................................................................32 5.3. Additional Manual (OPT 70).........................................................................................................................32 5.4. Extended Warranty (OPT 92) ......................................................................................................................32 5.5. NIST Traceable, Primary Standard CERTIFICATION .................................................................................32 OPERATING INSTRUCTIONS................................................................................................ 33 6. OPERATING THE M703E CALIBRATOR ......................................................................... 35 6.1. Test Functions..............................................................................................................................................36 05744 Rev B iii TELEDYNE API Table of Contents M703E Calibrator Operator’s Manual 6.2. Overview of Operating modes .....................................................................................................................37 6.3. STANDBY Mode ..........................................................................................................................................38 6.4. General Information about the GENERATE mode ......................................................................................39 6.4.1. GENERATE AUTO: Basic Generation of Calibration Gas................................................................39 6.5. AUTOMATIC CALIBRATION SEQUENCES ...............................................................................................40 6.5.1. SETUP SEQ: Programming Calibration Sequences.........................................................................40 6.5.1.1. Activating a Sequence from the M703E Front Panel .....................................................................41 6.5.1.2. Naming a Sequence .......................................................................................................................42 6.5.1.3. Setting the Repeat Count for a Sequence .....................................................................................43 6.5.1.4. Using the M703E’s Internal Clock to Trigger Sequences...............................................................44 6.5.1.5. Setting Up Control Inputs for a Sequence......................................................................................47 6.5.1.6. Setting Up Control Outputs for a Sequence...................................................................................48 6.5.1.7. Setting the PROGRESS Reporting Mode for the Sequences........................................................49 6.5.2. Adding Sequence Steps ........................................................................................................................50 6.5.2.1. The Generate Step .........................................................................................................................51 6.5.2.2. The STANDBY Step .......................................................................................................................52 6.5.2.3. The DURATION Step .....................................................................................................................52 6.5.2.4. The EXECSEQ Step.......................................................................................................................53 6.5.2.5. The CC OUTPUT Step ...................................................................................................................54 6.5.2.6. Deleting or Editing an Individual Step in a Sequence ....................................................................55 6.5.3. Deleting a Sequence .............................................................................................................................56 6.6. SETUP CFG ............................................................................................................................................57 6.7. SETUP CLK.............................................................................................................................................58 6.7.1. Setting the internal Clock’s Time and Day.............................................................................................58 6.7.2. Adjusting the internal Clock’s speed......................................................................................................59 6.8. SETUP PASS ..........................................................................................................................................60 6.9. SETUP DIAG TEST CHAN OUTPUT: Using the TEST Channel Analog Output...............................62 6.9.1. Configuring the TEST CHANNEL Analog Output..................................................................................62 6.9.1.1. The Analog I/O Configuration Submenu. .......................................................................................62 6.9.1.2. Selecting a Test Channel Function to Output ................................................................................64 6.9.1.3. TEST CHANNEL VOLTAGE RANGE Configuration......................................................................66 6.9.1.4. Turning the TEST CHANNEL Over-Range Feature ON/OFF ........................................................67 6.9.1.5. Adding a Recorder Offset to the TEST CHANNEL ........................................................................68 6.9.2. TEST CHANNEL CALIBRATION ..........................................................................................................69 6.9.2.1. Enabling or disabling the TEST CHANNEL Auto-Cal Feature .......................................................69 6.9.2.2. Automatic TEST CHANNEL Calibration.........................................................................................70 6.9.2.3. Manual Calibration of the TEST CHANNEL configured for Voltage Ranges .................................72 6.9.3. AIN Calibration.......................................................................................................................................74 6.10. SETUP MORE VARS: Internal Variables (VARS)............................................................................75 6.11. Operating the M703E Calibrator as an O3 Photometer .............................................................................77 6.11.1. Set up for Operating the M703E as an O3 Photometer .......................................................................77 6.12. SETUP LVL: Setting up and using LEADS (Dasibi) Operating Levels .................................................79 6.12.1. General Information about LEADS LEVELS .......................................................................................79 6.12.2. Dot commands.....................................................................................................................................79 6.12.3. Levels...................................................................................................................................................80 6.12.4. Activating an existing LEVEL...............................................................................................................80 6.12.5. Programming New LEVELS ................................................................................................................81 6.12.5.1. Creating a GENERATE LEVEL....................................................................................................82 6.12.5.2. Creating a MANUAL LEVEL.........................................................................................................83 6.12.5.3. Editing or Deleting a LEVEL.........................................................................................................84 6.12.6. Configuring LEVEL Status Blocks .......................................................................................................86 7. OPERATING THE M703E OVER THE SERIAL I/O PORTS.............................................. 87 7.1. Using the Analyser’s Communication Ports.................................................................................................87 7.1.1. RS-232 DTE and DCE Communication.................................................................................................87 7.1.2. COMM Port Default Settings and Connector Pin Assignments.............................................................88 7.1.3. COMM Port Baud Rate ..........................................................................................................................90 7.1.4. COMM Port Communication Modes ......................................................................................................91 7.1.5. COMM Port Testing ...............................................................................................................................93 iv 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Table of Contents 7.1.6. Machine ID.............................................................................................................................................94 7.1.7. Terminal Operating Modes ....................................................................................................................95 7.1.7.1. Help Commands in Terminal Mode................................................................................................95 7.1.7.2. Command Syntax ...........................................................................................................................96 7.1.7.3. Data Types .....................................................................................................................................96 7.1.7.4. Status Reporting.............................................................................................................................97 7.1.7.5. COM Port Password Security.........................................................................................................98 7.2. Remote Access by Modem ..........................................................................................................................99 7.3. Multidrop RS-232 Set Up .......................................................................................................................... 101 7.4. RS-485 Configuration of COM2 ................................................................................................................ 103 7.5. Remote Access via the Ethernet............................................................................................................... 105 7.5.1. Ethernet Card COM2 Communication Modes and Baud Rate ........................................................... 105 7.5.2. Configuring the Ethernet Interface Option using DHCP ..................................................................... 105 7.5.2.1. Manually Configuring the Network IP Addresses........................................................................ 108 7.5.3. Changing the Calibrator’s HOSTNAME.............................................................................................. 110 7.6. APICOM Remote Control Program........................................................................................................... 111 8. M703E CALIBRATION AND VERIFICATION .................................................................. 113 8.1. Verifying and Calibrating the M703E’s O3 Photometer............................................................................. 113 8.1.1. Setup for VERIFYING AND calibrating the O3 Photometer................................................................ 113 8.1.1.1. Calibration Manifold Exhaust/Vent Line ...................................................................................... 114 8.1.2. Verifying O3 Photometer Performance ............................................................................................... 115 8.1.3. Calibrating the O3 Photometer ............................................................................................................ 116 8.1.3.1. Photometer Zero Calibration ....................................................................................................... 116 8.1.3.2. Photometer Span Calibration ...................................................................................................... 117 8.1.4. O3 Photometer Dark Calibration ......................................................................................................... 118 8.2. Calibrating the O3 Generator .................................................................................................................... 119 8.2.1. O3 Generator Calibration table........................................................................................................... 119 8.2.2. Viewing O3 Generator Calibration Points............................................................................................ 120 8.2.3. Adding or Editing O3 Generator Calibration Points............................................................................. 121 8.2.4. Deleting O3 Generator Calibration Points ........................................................................................... 122 8.2.5. Turning O3 Generator Calibration Points ON / OFF ........................................................................... 123 8.2.6. Performing an Automatic Calibration of the O3 Generator ................................................................. 124 8.3. M703E Gas Pressure Sensor Calibration................................................................................................. 125 8.3.1.1. Gas Pressure Sensor Calibration Set Up.................................................................................... 125 8.3.2. Calibrating the Regulator and Photometer Pressure Sensors ........................................................... 127 8.4. M703E Gas Flow Calibration .................................................................................................................... 128 8.4.1. Calibrating the Photometer’s Sample Gas Flow................................................................................. 129 8.4.2. Calibrating the OuTput Gas Flow ....................................................................................................... 130 8.4.2.1. Output Gas Flow Set Up ............................................................................................................. 130 8.4.2.2. Performing an Output Gas Flow Calibration ............................................................................... 131 TECHNICAL INFORMATION................................................................................................ 133 9. THEORY OF OPERATION............................................................................................... 135 9.1. Pneumatic Operation ................................................................................................................................ 135 9.1.1. Gas Flow Control ................................................................................................................................ 135 9.1.1.1. Flow Control Assemblies ............................................................................................................. 135 9.1.1.2. Photometer Critical Flow Orifice.................................................................................................. 135 9.1.2. Internal Gas Pressure Sensors........................................................................................................... 136 9.2. Electronic Operation ................................................................................................................................. 137 9.2.1. Overview ............................................................................................................................................. 137 9.2.2. CPU .................................................................................................................................................... 138 9.2.2.1. Disk On Chip ............................................................................................................................... 139 9.2.2.2. Flash Chip ................................................................................................................................... 139 9.2.3. Relay PCA .......................................................................................................................................... 140 9.2.3.1. Valve Control ............................................................................................................................... 141 9.2.3.2. Heater Control ............................................................................................................................. 141 9.2.3.3. Relay PCA Status LEDs & Watch Dog Circuitry ......................................................................... 141 9.2.3.4. Relay PCA Watchdog Indicator (D1)........................................................................................... 142 05744 Rev B v TELEDYNE API Table of Contents M703E Calibrator Operator’s Manual 9.2.4. Motherboard........................................................................................................................................ 143 9.2.4.1. A to D Conversion ....................................................................................................................... 143 9.2.4.2. Sensor Inputs .............................................................................................................................. 143 9.2.4.3. Thermistor Interface .................................................................................................................... 143 9.2.4.4. Analog Outputs............................................................................................................................ 143 9.2.4.5. External Digital I/O....................................................................................................................... 144 9.2.4.6. I2C Data Bus ................................................................................................................................ 144 9.2.4.7. Power-up Circuit .......................................................................................................................... 144 9.2.5. Power Supply and Circuit Breaker...................................................................................................... 145 9.2.6. AC Power Configuration ..................................................................................................................... 146 9.2.6.1. AC configuration – Internal Pump (JP7)...................................................................................... 146 9.3. Front Panel Interface ................................................................................................................................ 147 9.3.1.1. Calibrator Status LEDs ................................................................................................................ 148 9.3.1.2. Keyboard ..................................................................................................................................... 148 9.3.1.3. Display......................................................................................................................................... 148 9.3.1.4. Keyboard/Display Interface Electronics....................................................................................... 149 9.4. Software Operation ................................................................................................................................... 150 9.5. O3 generator operation............................................................................................................................. 151 9.5.1. Principle of Photolytic O3 Generation ................................................................................................. 151 9.5.2. Generator Pneumatic Operation......................................................................................................... 152 9.5.3. O3 Generator Electronic Operation ..................................................................................................... 152 9.5.3.1. O3 Generator Temperature Control ............................................................................................. 154 9.6. Photometer Operation............................................................................................................................... 155 9.6.1. Measurement Method ......................................................................................................................... 155 9.6.1.1. Calculating O3 Concentration ...................................................................................................... 155 9.6.1.2. The Measurement / Reference Cycle.......................................................................................... 156 9.6.1.3. The Absorption Path.................................................................................................................... 158 9.6.1.4. Interferent Rejection .................................................................................................................... 158 9.6.2. Photometer Layout.............................................................................................................................. 159 9.6.3. Photometer Pneumatic Operation ...................................................................................................... 159 9.6.4. Photometer Electronic Operation........................................................................................................ 160 9.6.4.1. O3 Photometer Temperature Control .......................................................................................... 160 9.6.4.2. Pneumatic Sensors for the O3 Photometer ................................................................................. 161 10. MAINTENANCE SCHEDULE & PROCEDURES .......................................................... 163 10.1. Maintenance Schedule ........................................................................................................................... 163 10.2. Performing Leak Checks ........................................................................................................................ 167 10.2.1. Pressure Leak Check ....................................................................................................................... 167 10.3. Cleaning or replacing the Absorption Tube ............................................................................................ 171 10.4. Rebuilding the Dry Air Pump .................................................................................................................. 171 10.5. Photometer UV Source Lamp Adjustment.............................................................................................. 172 10.6. Photometer UV Source Lamp Replacement .......................................................................................... 173 10.7. Adjustment or Replacement of Ozone Generator UV Lamp .................................................................. 174 11. GENERAL TROUBLESHOOTING & REPAIR OF THE M703E CALIBRATOR ........... 177 11.1. General Troubleshooting ........................................................................................................................ 177 11.1.1. Fault Diagnosis with WARNING Messages...................................................................................... 178 11.1.2. Fault Diagnosis With Test Functions ................................................................................................ 180 11.1.3. Using the Diagnostic Signal I/O Function ......................................................................................... 182 11.2. Using the Analog Output Test Channel .................................................................................................. 183 11.3. Using the Internal Electronic Status LEDs.............................................................................................. 184 11.3.1. CPU Status Indicator ........................................................................................................................ 184 11.3.2. Relay PCA Status LEDs ................................................................................................................... 184 11.3.2.1. I2C Bus Watchdog Status LEDs ................................................................................................ 184 11.3.2.2. O3 Status LEDs ......................................................................................................................... 185 11.4. Subsystem Checkout.............................................................................................................................. 186 11.4.1. Verify Subsystem Calibration............................................................................................................ 186 11.4.2. AC Main Power ................................................................................................................................. 186 11.4.3. DC Power Supply.............................................................................................................................. 187 vi 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Table of Contents 11.4.4. I2C Bus .............................................................................................................................................. 188 11.4.5. Keyboard/Display Interface............................................................................................................... 188 11.4.6. Relay PCA ........................................................................................................................................ 189 11.4.7. PHOTOMETER O3 Generator Pressure /FLOW SENSOR Assembly ............................................ 189 11.4.8. Motherboard...................................................................................................................................... 191 11.4.8.1. A/D Functions ............................................................................................................................ 191 11.4.8.2. Test Channel / Analog Outputs Voltage .................................................................................... 191 11.4.8.3. Status Outputs........................................................................................................................... 192 11.4.8.4. Control Inputs ............................................................................................................................ 193 11.4.8.5. Control Outputs ......................................................................................................................... 194 11.4.9. CPU .................................................................................................................................................. 194 11.4.10. RS-232 Communications................................................................................................................ 195 11.4.10.1. General RS-232 Troubleshooting............................................................................................ 195 11.4.10.2. Troubleshooting Calibrator/Modem or Terminal Operation..................................................... 195 11.4.11. Temperature Problems ................................................................................................................... 196 11.4.11.1. Box / Chassis Temperature..................................................................................................... 196 11.4.11.2. Photometer Sample Chamber Temperature ........................................................................... 196 11.4.11.3. UV Lamp Temperature............................................................................................................ 196 11.4.11.4. Ozone Generator Temperature ............................................................................................... 197 11.5. Troubleshooting the O3 photometer........................................................................................................ 197 11.5.1. Dynamic Problems with the O3 photometer...................................................................................... 197 11.5.1.1. Noisy or Unstable O3 Readings at Zero .................................................................................... 197 11.5.1.2. Noisy, Unstable, or Non-Linear Span O3 Readings .................................................................. 198 11.5.1.3. Slow Response to Changes in Concentration........................................................................... 198 11.5.1.4. The Analog Output Signal Level Does Not Agree With Front Panel Readings......................... 198 11.5.1.5. Cannot Zero............................................................................................................................... 198 11.5.1.6. Cannot Span.............................................................................................................................. 198 11.5.2. Checking Measure / REFERENCE VALVE...................................................................................... 199 11.6. Troubleshooting the O3 Generator.......................................................................................................... 200 11.6.1. Checking The UV Lamp Power Supply ............................................................................................ 200 11.7. Trouble Shooting the Optional O3 generator .......................................................................................... 201 11.7.1. Checking The UV Source Lamp Power Supply................................................................................ 201 11.8. Repair Procedures.................................................................................................................................. 202 11.8.1. Repairing Sample Flow Control Assembly ....................................................................................... 202 11.8.2. Disk-On-Chip Replacement Procedure ............................................................................................ 203 11.9. Technical Assistance .............................................................................................................................. 203 12. A PRIMER ON ELECTRO-STATIC DISCHARGE......................................................... 205 12.1. How Static Charges are Created............................................................................................................ 205 12.2. How Electro-Static Charges Cause Damage ......................................................................................... 206 12.3. Common Myths About ESD Damage ..................................................................................................... 207 12.4. Basic Principles of Static Control............................................................................................................ 207 12.4.1. General Rules ................................................................................................................................... 207 12.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance ................................................. 209 12.4.2.1. Working at the Instrument Rack ................................................................................................ 209 12.4.2.2. Working at an Anti-ESD Work Bench........................................................................................ 209 12.4.2.3. Transferring Components from Rack to Bench and Back......................................................... 210 12.4.2.4. Opening Shipments from Teledyne Instruments Customer Service. ........................................ 210 12.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service.......................... 211 05744 Rev B vii TELEDYNE API Table of Contents M703E Calibrator Operator’s Manual LIST OF FIGURES Figure 3-1: Figure 3-2: Figure 3-3: Figure 3-4: Figure 3-5: Figure 3-6: Figure 3-7: Figure 3-8: Figure 3-9: Figure 3-10: Figure 5-1: Figure 5-1: Figure 5-2: Figure 5-3: Figure 6-1: Figure 6-2: Figure 6-3: Figure 6-4: Figure 6-5: Figure 7-1: Figure 7-2: Figure 7-3: Figure 7-4: Figure 7-5: Figure 7-6: Figure 7-7: Figure 7-8: Figure 8-1: Figure 8-2: Figure 8-3: Figure 8-4: Figure 8-5: Figure 9-1: Figure 9-2: Figure 9-3: Figure 9-4: Figure 9-5: Figure 9-6: Figure 9-7: Figure 9-8: Figure 9-9: Figure 9-10: Figure 9-11: Figure 9-12: Figure 9-13: Figure 9-14: Figure 9-15: Figure 9-16: Figure 9-17: Figure 9-18: Figure 9-19: Figure 9-20: Figure 9-21: Figure 9-22: Figure 10-2: Figure 10-3: viii M703E Front Panel Layout ................................................................................................................10 M703E Rear Panel Layout.................................................................................................................10 M703E Internal Layout – Top View ...................................................................................................11 M703E Pneumatic Diagram...............................................................................................................12 M703E the TEST CHANNEL Connector ...........................................................................................13 Status Output Connector ...................................................................................................................14 M703E Digital Control Input Connectors ...........................................................................................16 M703E Digital Control Output Connector ..........................................................................................17 Basic Pneumatic Setup of M703E .....................................................................................................19 Location of Pressure Regulator Adjustment Knob.............................................................................26 M703E with Carrying Strap Handle and Rack Mount Brackets.........................................................29 M703E Multidrop Card.......................................................................................................................30 M703E Ethernet Card ........................................................................................................................31 M703E Rear Panel with Ethernet Installed........................................................................................31 Front Panel Display ...........................................................................................................................37 M703E the TEST CHANNEL Connector ...........................................................................................62 Setup for Calibrating the TEST CHANNEL .......................................................................................72 Set up for Using the M703E to Measure an External O3 Source ......................................................77 LEADS Level Display Format ............................................................................................................85 Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) ................88 Default Pin Assignments for CPU COM Port connector (RS-232). ...................................................88 Location of JP2 on RS232-Multidrop PCA (option 62) ................................................................... 101 RS232-Multidrop PCA Host/Calibrator Interconnect Diagram........................................................ 102 CPU card Locations of RS-232/485 Switches, Connectors and Jumpers...................................... 103 Back Panel connector Pin-Outs for COM2 in RS-485 mode.......................................................... 104 CPU connector Pin-Outs for COM2 in RS-485 mode..................................................................... 104 APICOM Remote Control Program Interface ................................................................................. 111 Set up for Verifying Optional O3 Photometer Using Internal O3 Generator .................................... 114 Set up for Verifying Optional O3 Photometer Using an External O3 Generator.............................. 114 Pressure Calibration Monitor Points ............................................................................................... 125 O3 Generator Pressure Monitor Point Physical Location– M703E ................................................. 126 Output Flow Calibration Monitor Point............................................................................................ 130 Location of Gas Flow Control Assemblies...................................................................................... 135 M703E Electronic Block Diagram ................................................................................................... 137 M703E CPU Board Annotated........................................................................................................ 138 Relay Board PCA with AC Relay Retainer Removed..................................................................... 140 Heater Control Loop Block Diagram............................................................................................... 141 Status LED Locations – Relay PCA ............................................................................................... 141 M703E Power Distribution Block diagram ...................................................................................... 145 Location of the AC Configuration Jumper for the Dry Air Pump.................................................... 146 Pump AC Power Jumpers (JP7).................................................................................................... 147 M703E Front Panel Layout ............................................................................................................. 147 Keyboard and Display Interface Block Diagram ............................................................................. 149 Schematic of Basic Software Operation ......................................................................................... 150 O3 Generator Internal Pneumatics.................................................................................................. 151 O3 Generator Valve and Gas Fixture Locations ............................................................................. 152 O3 Generator Electronic Block Diagram ......................................................................................... 153 O3 Generator Electronic Components Location ............................................................................. 153 O3 Generator Temperature Thermistor and DC Heater Locations ................................................. 154 O3 Photometer Gas Flow – Measure Cycle.................................................................................... 157 O3 Photometer Gas Flow – Reference Cycle ................................................................................. 157 O3 Photometer Absorption Path ..................................................................................................... 158 O3 Photometer Layout – Top Cover Removed............................................................................... 159 O3 Photometer Electronic Block Diagram....................................................................................... 160 Pneumatic setup for performing Pressure Leak Checks ................................................................ 170 Photometer – Location of UV Detector Gain Adjustment & UV Lamp Set Screw ........................... 173 05744 Rev B M703E Calibrator Operator’s Manual Figure 10-4: Figure 10-5: Figure 11-1: Figure 11-2: Figure 11-3: Figure 11-4: Figure 11-5: Figure 12-1: Figure 12-2: TELEDYNE API Table of Contents O3 Generator Temperature Thermistor and DC Heater Locations ................................................. 174 Location of O3 Generator Reference Detector Adjustment Pot ...................................................... 174 Example of Signal I/O Function ...................................................................................................... 182 CPU Status Indicator ...................................................................................................................... 184 Relay PCA Status LEDS Used for Troubleshooting ....................................................................... 185 Location of DC Power Test Points on Relay PCA .......................................................................... 187 Critical Flow Restrictor Assembly Disassembly.............................................................................. 202 Triboelectric Charging..................................................................................................................... 205 Basic anti-ESD Work Station .......................................................................................................... 207 LIST OF TABLES Table 2-1: Table 2-2: Table 2-3: Table 2-4: Table 3-1: Table 3-2: Table 3-3: Table 3-4: Table 3-5: Table 6-1: Table 6-2: Table 6-3: Table 6-4: Table 6-5: Table 6-6: Table 6-7: Table 6-8: Table 6-9: Table 6-10: Table 6-11: Table 7-1: Table 7-2: Table 7-3: Table 7-4: Table 7-5: Table 8-1: Table 8-2: Table 9-1: Table 9-2: Table 9-3: Table 9-4: Table 10-1: Table 11-1: Table 11-2: Table 11-3: Table 11-4: Table 11-5: Table 11-6: Table 11-7: Table 11-8: Table 11-9: Table 11-10: Table 11-11: 05744 Rev B M703E Analytical Specifications..........................................................................................................5 M703E Electrical and Physical Specifications .....................................................................................5 M703E Specifications for Ozone Generator ........................................................................................6 M703E Specifications for O3 Photometer ............................................................................................6 Status Output Pin Assignments .........................................................................................................14 M703E Control Input Pin Assignments..............................................................................................15 M703E Control Input Pin Assignments..............................................................................................17 Front Panel Display during System Warm-Up...................................................................................22 Possible Warning Messages at Start-Up...........................................................................................23 Test Functions Defined......................................................................................................................36 Calibrator Operating Modes...............................................................................................................37 Automatic Calibration SEQUENCE Set Up Attributes .......................................................................40 Calibration SEQUENCE Step Instruction ..........................................................................................40 Sequence Progress Reporting Mode ................................................................................................49 Password Levels................................................................................................................................60 DIAG - Analog I/O Functions .............................................................................................................62 Test Channels Functions Available on the M703E’s Analog Output .................................................64 Analog Output Voltage Range Min/Max ............................................................................................66 Voltage Tolerances for the TEST CHANNEL Calibration..................................................................72 Variable Names (VARS) ....................................................................................................................75 COMM Port Communication Modes ..................................................................................................91 Terminal Mode Software Commands ................................................................................................95 Teledyne Instruments Serial I/O Command Types............................................................................96 Ethernet Status Indicators .............................................................................................................. 105 LAN/Internet Configuration Properties............................................................................................ 106 M703E Pressure Sensors............................................................................................................... 125 M703E Gas Pressure to Output Flow conversion Table ................................................................ 128 Relay Board Status LEDs ............................................................................................................... 142 AC Power Configuration for Internal Pumps (JP7) ......................................................................... 146 Front Panel Status LEDs ................................................................................................................ 148 M703E Photometer Measurement / Reference Cycle .................................................................... 156 M703E Maintenance Schedule....................................................................................................... 165 Front Panel Warning Messages ..................................................................................................... 179 Test Functions - Indicated Failures ................................................................................................ 180 Test Channel Outputs as Diagnostic Tools .................................................................................... 183 Relay PCA Watchdog LED Failure Indications............................................................................... 184 Relay PCA Status LED Failure Indications..................................................................................... 185 DC Power Test Point and Wiring Color Codes............................................................................... 187 DC Power Supply Acceptable Levels ............................................................................................. 188 Relay PCA Control Devices............................................................................................................ 189 Analog Output Test Function - Nominal Values Voltage Outputs .................................................. 192 Status Outputs Check..................................................................................................................... 192 M703E Control Input Pin Assignments and Corresponding Signal I/O Functions ......................... 193 ix TELEDYNE API Table of Contents M703E Calibrator Operator’s Manual Table 11-12: Control Outputs Pin Assignments and Corresponding Signal I/O Functions Check ...................... 194 Table 12-1: Static Generation Voltages for Typical Activities ............................................................................ 205 Table 12-2: Sensitivity of Electronic Devices to Damage by ESD ..................................................................... 206 x 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Table of Contents LIST OF APPENDICES APPENDIX A - VERSION SPECIFIC SOFTWARE DOCUMENTATION APPENDIX A-1: Model 703E Software Menu Trees, Revision C.0 APPENDIX A-2: Model 703E Setup Variables Available Via Serial I/O, Revision C.0 APPENDIX A-3: Model 703E Warnings and Test Measurements via Serial I/O, Revision C.0 APPENDIX A-4: Model 703E Signal I/O Definitions, Revision C.0 APPENDIX A-5: Model 703E Terminal Command Designators, Revision C.0 APPENDIX B - Model 703E SPARE PARTS LIST APPENDIX C - Model 703E REPAIR QUESTIONNAIRE APPENDIX D - Model 703E ELECTRONIC SCHEMATICS USER NOTES: 05744 Rev B xi TELEDYNE API Table of Contents M703E Calibrator Operator’s Manual USER NOTES: xii 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API GENERAL INFORMATION SECTION I – GENERAL INFORMATION 05744 Rev B 1 TELEDYNE API GENERAL INFORMATION M703E Calibrator Operator’s Manual USER NOTES 2 05744 Rev B TELEDYNE API Introduction M703E Calibrator Operator’s Manual 1. INTRODUCTION 1.1. M703E CALIBRATOR OVERVIEW The Model 703E is a microprocessor-based ozone calibrator for calibration of ambient ozone analyzers, such as the T-API M400E. The M703E features an internal ozone photometer that provides very accurate closed loop feedback control of the ozone concentration. As many as 50 independent calibration sequences may be programmed into the M703E, covering time periods of up to one year. The setup of sequences is simple and intuitive. These sequences may be actuated manually, automatically, or by a remote signal. The sequences may be uploaded remotely, including remote editing. All programs are maintained in non-volatile memory. The M703E design emphasizes fast response, repeatability, overall accuracy and ease of operation. It may be combined with the Model 701 Zero Air Generator to provide the ultimate in easy to use, precise calibration for your ozone analyzers. Some of the exceptional features of your M703E Photometric O3 Calibrator are: Advanced E Series electronics Lightweight for transportability Optional Ethernet connectivity 12 independent timers for sequences Nested sequences (up to 5 levels) Internal ozone generator and photometer allows use as primary or transfer standard 1.2. USING THIS MANUAL NOTE Throughout this manual, words printed in capital, bold letters, such as SETUP or ENTR represent messages as they appear on the calibrator’s display. This manual is organized in the following manner: TABLE OF CONTENTS: Outlines the contents of the manual in the order the information is presented. This is a good overview of the topics covered in the manual. There is also a list of appendices, figures and tables. In the electronic version of the manual, clicking on any of these table entries automatically views that section. SECTION I – GENERAL INFORMATION INTRODUCTION A brief description of the M703E calibrator architecture as well as a description of the layout of the manual and what information is located in its various sections and chapters. SPECIFICATIONS AND WARRANTY Teledyne Instruments’ warranty statement. 05744 Rev B 3 TELEDYNE API Introduction M703E Calibrator Operator’s Manual GETTING STARTED Instructions for setting up, installing and running your calibrator for the first time. GLOSSARY: Answers to the most frequently asked questions about operating the calibrator and a glossary of acronyms and technical terms. OPTIONAL HARDWARE & SOFTWARE A description of optional equipment to add functionality to your calibrator. SECTION II – OPERATING INSTRUCTIONS USING THE M703E CALIBRATOR Step-by-Step instructions for using the display/keyboard to set up and operate the M703E calibrator. REMOTE OPERATION OF THE M703E CALIBRATOR Information and instructions for interacting with the M703E calibrator via its several remote interface options (e.g. via RS-232, Ethernet, its built in digital control inputs/outputs, etc.) M703E VALIDATION AND VERIFICATION Methods and procedures for validating and verifying the correct operation of your M703E Photometric O3 Calibrator SECTION III – TECHNICAL INFORMATION THEORY OF OPERATION An in-depth look at the various principals by which your calibrator operates as well as a description of how the various electronic, mechanical and pneumatic components of the calibrator work and interact with each other. A close reading of this section is invaluable for understanding the calibrator’s operation. MAINTENANCE SCHEDULE AND PROCEDURES Description of preventative maintenance procedures that should be regularly performed on you calibrator to assure good operating condition. GENERAL TROUBLESHOOTING & REPAIR OF THE M703E CALIBRATOR This section includes pointers and instructions for diagnosing problems with the calibrator in general as well as instructions on performing repairs. A PRIMER ON ELECTRO-STATIC DISCHARGE This section describes how static electricity occurs; why it is a significant concern and; how to avoid it and avoid allowing ESD to affect the reliable and accurate operation of your calibrator. APPENDICES For easier access and better updating, some information has been separated out of the manual and placed in a series of appendices at the end of this manual. These include version-specific software menu trees, warning messages, serial I/O variables as well as spare part listings, repair questionnaires, interconnect drawing, detailed pneumatic and electronic schematics. USER NOTES: 4 05744 Rev B TELEDYNE API Specifications, Approvals and Warranty M703E Calibrator Operator’s Manual 2. SPECIFICATIONS, APPROVALS AND WARRANTY 2.1. SPECIFICATIONS Table 2-1: M703E Analytical Specifications Linearity +/- 1.0% of full scale Precision 1.0 ppb Stability +/- 2.0 ppb (photometer feedback mode) Response Time 180 seconds to 95% Stability (7-days) 1% photometer feedback; 3% without photometer feedback (CNST or REF) Table 2-2: M703E Electrical and Physical Specifications Temperature Range 5-40ºC Humidity Range 0 - 95% RH, non-condensing Dimensions (HxWxD) 7” (178 mm) x 17” (432 mm) x 24” (609 mm) Operating Altitude 10,000 ft Maximum Weight AC Power 35.5 lbs (16.1 kg) including internal zero air pump 115VAC, 60Hz 230VAC,50HZ Analog Outputs 1 user configurable output Analog Output Ranges 0.1 V, 1 V, 5 V or 10 V Range with 5% under/over-range Analog Output Resolution 1 part in 4096 of selected full-scale voltage (12 bit) Digital Control Outputs 12 opto-isolated outputs Digital Control Inputs 12 opto-isolated outputs Status Outputs 12 opto-isolated outputs, 5 defined, 7 spare Serial I/O 2 ports: 1x RS-232; 1x RS-485 or RS-232 (configurable) Communication speed: 300 - 115200 baud (user selectable) Certifications EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B Section 15.107 Class A, ICES-003 Class A (ANSI C63.4 1992) & AS/NZS 3548 (w/A1 & A2; 97) Class A. IEC 61010-1:90 + A1:92 + A2:95, 05744 Rev B 5 TELEDYNE API Specifications, Approvals and Warranty Table 2-3: M703E Specifications for Ozone Generator Maximum Output 6 ppm LPM Minimum Output 100 ppb LPM Response Time: 180 Sec. (98%) Optical Feedback Standard Table 2-4: M703E Calibrator Operator’s Manual M703E Specifications for O3 Photometer Full Scale Range 100 ppb to 10 ppm ; User Selectable Precision 1.0 ppb Linearity 1.0% of Full Scale Rise/Fall Time <20 sec (photometer response) Zero Drift <1.0 ppb / 7 days Span Drift <1% / 24 hours; <2% / 7 days Minimum Gas Flow Required 800 cc3/min 2.2. CE MARK COMPLIANCE EMISSIONS COMPLIANCE The Teledyne Instruments’ M703E Photometric O3 Calibrator is designed to be fully compliant with: EN61326 (1997 w/A1: 98) Class A, FCC Part 15 Subpart B Section 15.107 Class A, ICES-003 Class A (ANSI C63.4 1992) & AS/NZS 3548 (w/A1 & A2; 97) Class A. Test status: Pending. SAFETY COMPLIANCE The Teledyne Instruments’ M703E Photometric O3 Calibrator is designed to be fully compliant with: IEC 61010-1:90 + A1:92 + A2:95, Test status: Pending. 6 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Specifications, Approvals and Warranty 2.3. WARRANTY WARRANTY POLICY (02024D) Prior to shipment, T-API equipment is thoroughly inspected and tested. Should equipment failure occur, T-API assures its customers that prompt service and support will be available. COVERAGE After the warranty period and throughout the equipment lifetime, T-API stands ready to provide on-site or in-plant service at reasonable rates similar to those of other manufacturers in the industry. All maintenance and the first level of field troubleshooting is to be performed by the customer. NON-API MANUFACTURED EQUIPMENT Equipment provided but not manufactured by T-API is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty. GENERAL During the warranty period, T-API warrants each Product manufactured by T-API to be free from defects in material and workmanship under normal use and service. Expendable parts are excluded. If a Product fails to conform to its specifications within the warranty period, API shall correct such defect by, in API's discretion, repairing or replacing such defective Product or refunding the purchase price of such Product. The warranties set forth in this section shall be of no force or effect with respect to any Product: (i) that has been altered or subjected to misuse, negligence or accident, or (ii) that has been used in any manner other than in accordance with the instruction provided by T-API, or (iii) not properly maintained. THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY, WHETHER EXPRESSED OR IMPLIED. THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN. API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF T-API'S PERFORMANCE HEREUNDER, WHETHER FOR BREACH OF WARRANTY OR OTHERWISE TERMS AND CONDITIONS All units or components returned to Teledyne Instruments Incorporated should be properly packed for handling and returned freight prepaid to the nearest designated Service Center. After the repair, the equipment will be returned, freight prepaid. USER NOTES: 05744 Rev B 7 TELEDYNE API Specifications, Approvals and Warranty M703E Calibrator Operator’s Manual USER NOTES: 8 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3. GETTING STARTED 3.1. UNPACKING AND INITIAL SETUP CAUTION THE M703E WEIGHS ABOUT 16.1 KG (35.5 POUNDS) WITHOUT OPTIONS INSTALLED. TO AVOID PERSONAL INJURY, WE RECOMMEND USING TWO PERSONS TO LIFT AND CARRY THE CALIBRATOR. 1. Inspect the received packages for external shipping damage. If damaged, please advise the shipper first, then Teledyne Instruments. 2. Included with your calibrator is a printed record of the final performance characterization performed on your instrument at the factory. This record, titled Final Test and Validation Data Sheet (P/N 05760) is an important quality assurance and calibration record for this instrument. It should be placed in the quality records file for this instrument. 3. Carefully remove the top cover of the calibrator and check for internal shipping damage. Remove the set-screw located in the top, center of the Front panel. Remove the 2 screws fastening the top cover to the unit (one per side towards the rear). Slide the cover backwards until it clears the calibrator’s front bezel. Lift the cover straight up. NOTE Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. See Chapter 12 for more information on preventing ESD damage. CAUTION NEVER DISCONNECT ELECTRONIC CIRCUIT BOARDS, WIRING HARNESSES OR ELECTRONIC SUBASSEMBLIES WHILE THE UNIT IS UNDER POWER. 4. Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated. 5. Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated. 6. Verify that all of the optional hardware ordered with the unit has been installed. These are checked on the paperwork accompanying the calibrator. 05744 Rev B 9 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual VENTILATION CLEARANCE: Whether the calibrator is set up on a bench or installed into an instrument rack, be sure to leave sufficient ventilation clearance. AREA MINIMUM REQUIRED CLEARANCE Back of the instrument 10 cm / 4 inches Sides of the instrument 2.5 cm / 1 inch Above and below the instrument. 2.5 cm / 1 inch Various rack mount kits are available for this calibrator. See Chapter 5 of this manual for more information. 3.1.1. MODEL 703E CALIBRATOR FASTENER MODE FIELD KEY DEFINITION FIELD LOCKING SCREW KEYBOARD Figure 3-1: O3 Outlet to Photometer Photometer O3 Inlet MESSAGE FIELD ON / OFF SWITCH FASTENER STATUS LED’s M703E Front Panel Layout O3 Generator Photometer Gas Status Outputs Control Outputs Analog Output Optional Ethernet Connectors Exhaust Card FAN AC Power Connector Cal Gas Outlets Inlet for Dry Air Inlet for External Zero Air Source Figure 3-2: 10 DCE-DTE COMM Ports Control Inputs Serial No. Tag Switch M703E Rear Panel Layout 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual Ethernet PCA installed here (Optional) AC Power Connector Gas Inlets & Outlets Photometer Pump Back Panel Motherboard Relay PCA CPU PCA O3 Generator & Photometer, Pressure/Flow Sensor PCA O3 Generator O3 Generator Assembly Dry Air Pump Inlet Photometer M/R Valve DC Power supplies Dry Air Pump Outlet O3 Generator Lamp Driver PHOTOMETER Dry Air Pump Pressure Regulator Inlet Outlet to O3 Generator Check Valve 1 LPM Flow Control Assy. Inlet to Regulator ON / OFF Switch Front Panel 5 LPM Flow Control Assy. Pressure Regulator Inlet Figure 3-3: 05744 Rev B DFU Filters Charcoal Scrubber on Top M703E Internal Layout – Top View 11 O3 FLOW SENSOR O3 Generator Assembly Flow Control (100 cm3/min) Flow Control (1.0 to 2.0 LPM) Flow Control (5.0 lpm) O3 GENERATOR CHARCOAL SCRUBBER M703E Pneumatic Diagram Figure 3-4: 05744 Rev B 12 M703E Calibrator Operator’s Manual TELEDYNE API Getting Started TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.2. ELECTRICAL CONNECTIONS 3.2.1. POWER CONNECTION Verify the correct line voltage and frequency configuration on the serial number tag on the rear panel of the M703E. Attach the power cord to the calibrator and plug it into a power outlet capable of carrying at least 10 A current at your AC voltage and that it is equipped with a functioning earth ground. CAUTION HIGH VOLTAGES ARE PRESENT INSIDE THE CALIBRATORS CASE POWER CONNECTION MUST HAVE FUNCTIONING GROUND CONNECTION. DO NOT DEFEAT THE GROUND WIRE ON POWER PLUG. TURN OFF CALIBRATOR POWER BEFORE DISCONNECTING OR CONNECTING ELECTRICAL SUBASSEMBLIES. CAUTION DO NOT LOOK AT THE PHOTOMETER UV LAMP. UV LIGHT CAN CAUSE EYE DAMAGE. ALWAYS WEAR GLASSES MADE FROM SAFETY UV FILTERING GLASS (PLASTIC GLASSES WILL NOT DO). 3.2.2. ANALOG OUTPUT TEST CHANNEL CONNECTIONS The M703E is equipped with an analog output channel accessible through a connector on the back panel of the instrument. The standard configuration for this output is 0-5 VDC. It can be set by the user to output one of a variety of diagnostic test functions (see Section 6.9.) To access these signals attach a strip chart recorder and/or data-logger to the appropriate analog output connections on the rear panel of the calibrator. Pin-outs for the analog output connector at the rear panel of the instrument are: ANALOG OUT + Figure 3-5: 05744 Rev B – M703E the TEST CHANNEL Connector 13 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.2.3. CONNECTING THE STATUS OUTPUTS The status outputs report calibrator conditions via optically isolated NPN transistors, which sink up to 50 mA of DC current. These outputs can be used interface with devices that accept logic-level digital inputs, such as programmable logic controllers (PLC’s). Each Status bit is an open collector output that can withstand up to 40 VDC. All of the emitters of these transistors are tied together and available at D. NOTE Most PLC’s have internal provisions for limiting the current that the input will draw from an external device. When connecting to a unit that does not have this feature, an external dropping resistor must be used to limit the current through the transistor output to less than 50 mA. At 50 mA, the transistor will drop approximately 1.2V from its collector to emitter. The status outputs are accessed via a 12-pin connector on the calibrator’s rear panel labeled STATUS. The function of each pin is defined in Table 3-1. Figure 3-6: CALIBRATOR + INRTERNAL GROUND D + 5 VDC 8 EMITTER BUSS 7 Unassigned 6 Unassigned 5 PRESS ALARM 4 TEMP ALARM 3 DIAG 2 CAL ACTIVE SYSTEM OK 1 POWER OK STATUS Status Output Connector The pin assignments for the Status Outputs are: Table 3-1: OUTPUT # STATUS DEFINITION 1 2 3 4 5 6 7&8 D SYSTEM OK Unassigned CAL ACTIVE DIAG TEMP ALARM PRESS ALARM Unassigned Emitter BUSS The emitters of the transistors on pins 1 to 8 are bussed together. Digital Ground The ground level from the calibrator’s internal DC power supplies. Emitter BUSS DC POWER The emitters of the transistors on pins 9 to 16 are bussed together. + 5 VDC D + 14 Status Output Pin Assignments CONDITION On, if no faults are present. On if the calibrator is in GENERATE mode On if the calibrator is in DIAGNOSTIC mode On whenever a temperature alarm is active. On whenever gas pressure alarm is active 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.2.4. CONNECTING THE CONTROL INPUTS The calibrator is equipped with 12 digital control inputs that can be used to Initiate various user programmable calibration sequences (see Section 6.5.1.5 for instructions on assigning the control inputs to specific calibration sequences). Access to these inputs is via 2 separate 10-pin connectors, labeled CONTROL IN, that are located on the calibrator’s rear panel. Table 3-2: M703E Control Input Pin Assignments CONNECTOR INPUT DESCRIPTION Top 1 to 6 Can be used as either 6 separate on/off switches or as bits 1 through 6 of a 12 bit wide binary activation code (see Section 6.5.1.5) Bottom 7 to 12 Can be used as either 6 separate on/off switches or as bits 7 through 12 of a 12 bit wide binary activation code (see Section 6.5.1.5) BOTH Chassis ground. Top U Input pin for +5 VDC required to activate pins A – F. This can be from an external source or from the “+” pin of the instruments STATUS connector. Bottom U Input pin for +5 VDC required to activate pins G – L. This can be from an external source or from the “+” pin of the instruments STATUS connector. BOTH + Internal source of +5V that can be used to actuate control inputs when connected to the U pin. 05744 Rev B 15 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual There are two methods for energizing the control inputs. The internal +5V available from the pin labeled “+” is the most convenient method. However, if full isolation is required, an external 5 VDC power supply should be used. CONTROL Bit-06 CONTROL Bit-05 4 5 6 U + 7 8 9 10 11 12 U + 7 8 9 10 11 12 U + Figure 3-7: CONTROL Bit-12 3 CONTROL Bit-11 2 CONTROL Bit-10 1 CONTROL Bit-09 + CONTROL Bit-08 U CONTROL Bit-07 6 CONTROL Bit-12 5 CONTROL Bit-11 4 CONTROL Bit-10 3 CONTROL Bit-09 2 - 16 CONTROL Bit-04 CONTROL Bit-03 CONTROL Bit-02 CONTROL Bit-01 CONTROL Bit-06 CONTROL Bit-05 CONTROL Bit-04 CONTROL Bit-03 CONTROL Bit-02 Example of External Power Connections 1 CONTROL Bit-08 CONTROL Bit-07 CONTROL Bit-01 Example of Local Power Connections 5 VDC Power Supply + M703E Digital Control Input Connectors 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.2.5. CONNECTING THE CONTROL OUTPUTS The calibrator is equipped with 12 opto-isolated, digital control outputs. These outputs are activated by the M703E’s user-programmable, calibration sequences (see Section 6.5.1.6 for instructions on assigning the control outputs to specific calibration sequences) These outputs may be used to interface with devices that accept logic-level digital inputs, such as programmable logic controllers (PLC’s), dataloggers, or digital relays/valve drivers. They are accessed via a 14-pin connector on the calibrator’s rear panel (see Figure 3-2). CONTROL OUTPUTS 1 2 3 4 5 Figure 3-8: 6 7 8 9 10 11 12 E M703E Digital Control Output Connector NOTE Most PLC’s have internal provisions for limiting the current the input will draw. When connecting to a unit that does not have this feature, external resistors must be used to limit the current through the individual transistor outputs to ≤50mA (120 Ω for 5V supply). The pin assignments for the control outputs are: Table 3-3: M703E Control Input Pin Assignments PIN # STATUS DEFINITION 1 - 12 Outputs 1 through 12 respectively E Emitter BUSS The emitters of the transistors on pins 1 to 8 are bussed together. Digital Ground The ground level from the calibrator’s internal DC power supplies. 05744 Rev B CONDITION Closed if the sequence or sequence step activating output is operating 17 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.2.6. CONNECTING THE SERIAL PORTS If you wish to utilize either of the calibrator’s two serial interface COMM ports, refer to Section 7.1 of this manual for instructions on their configuration and usage. 3.2.7. CONNECTING TO A LAN OR THE INTERNET If your unit has a Teledyne Instruments Ethernet card (Option 63 and 64), plug one end into the 7’ CAT5 cable supplied with the option into the appropriate place on the back of the calibrator and the other end into any nearby Ethernet access port. NOTE: The M703E firmware supports dynamic IP addressing or DHCP. If your network also supports DHCP, the calibrator will automatically configure its LAN connection appropriately, If your network does not support DHCP, see Section 7.5.2.1 for instructions on manually configuring the LAN connection. 3.2.8. CONNECTING TO A MULTIDROP NETWORK If your unit has a Teledyne Instruments RS-232 multidrop card (Option 62), see Section 7.3 for instructions on setting it up. 18 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.3. PNENUMATIC CONNECTIONS Figure 3-9: Basic Pneumatic Setup of M703E 3.3.1. DRY AIR IN When using the internal zero air pump, a source of dry air should be connected to the port labeled ‘Dry Air In’ on the rear panel. This air should be supplied at atmospheric pressure. The supplied air should have a dew point of –20 C or less. Teledyne API can supply an optional desiccant cartridge that can be used to supply dry air to the M703E. 3.3.2. ZERO AIR IN An external pressurized source of zero air can be supplied at the ‘Zero Air” port on the rear panel. This is the standard configuration when the zero air pump is not installed. This zero air should be scrubbed of ozone and have a dew point of -20 C or less. The pressure of the zero air should be regulated to 20-35 psig. NOTE When connecting an external source of zero air to an M703E with an internal zero air pump installed, the zero air pump should be disabled. The “ZA_PUMP_ENABLE” VAR (see Section 6.10) should be set to OFF. 05744 Rev B 19 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.3.3. OUTPUT MANIFOLD A four-port output manifold is supplied on the rear panel of the M703E enabling simultaneous testing of up to two external analyzers. Sample lines for ozone analyzers to be calibrated can be connected directly to this manifold. To prevent ozone exposure, the bottom port of this manifold is used as a vent and should be connected to a proper unpressurized vent manifold. It is important that the backpressure at this vent fitting be kept to a minimum. If a vent line longer than 2 meters (~6 feet) is required, then 3/8” OD tubing should be used. Any unused ports on this manifold must be capped. 3.3.4. EXHAUST The port labeled ‘EXHAUST’ contains the exhaust gas from the internal photometer and may contain ozone. This port should be connected to a proper unpressurized vent manifold to prevent ozone exposure. 3.3.5. MEASURING AN EXTERNAL OZONE SOURCE The M703E can easily be configured to measure an external source of ozone. See Section 6.11 for details on operating the M703E in this manner. USER NOTES 20 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.4. INITIAL OPERATION If you are unfamiliar with the M703E theory of operation, we recommend that you read Chapter 9. For information on navigating the calibrator’s software menus, see the menu trees described in Appendix A.1. 3.4.1. START-UP After all of the electrical and pneumatic connections are made, turn on the instrument. The exhaust fan and should start immediately. If the instrument is equipped with an internal photometer installed, the associated pump should also start up. The display should immediately display a single, horizontal dash in the upper left corner of the display. This will last approximately 30 seconds while the CPU loads the operating system. Once the CPU has completed this activity, it will begin loading the calibrator firmware and configuration data. During this process, string of messages will appear on the calibrator’s front panel display: SELECT START OR REMOTE : 3 START . CHECKING FLASH STATUS : 1 STARTING INSTRUMENT CODE : 1 STARTING INSTRUMENT W/FLASH : 1 System waits 3 seconds then automatically begins its initialization routine. No action required. System is checking the format of the instrument’s flash memory chip. If at this point, **FLASH FORMAT INVALID** appears, contact T–API customer service The instrument is loading configuration and calibration data from the flash chip The instrument is loading the calibrator firmware. M703E CALIBRATOR BOOT PROGRESS [XXXXX 50%_ _ _ _ _] The revision level of the firmware installed in your analyzer is briefly displayed SOFTWARE REVISION B.0 BOOT PROGRESS [XXXXXXXX 80% _ _] STANDBY TEST SYSTEM RESET GEN STBY SEQ MSG CLR SETUP Firmware fully booted Press CLR to clear initial warning messages. The calibrator should automatically switch to STANDBY mode after completing the boot-up sequence. 05744 Rev B 21 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.4.2. WARM UP The M703E Photometric calibrator requires a minimum of 30 minutes for all of its internal components to reach a stable operating temperature. During that time, various portions of the instrument’s front panel will behave as follows. See Figure 3-1 for locations. Table 3-4: Name Color Main Message Field N/A Mode Field N/A Front Panel Display during System Warm-Up Behavior Significance Displays Warning messages and Test Function values Displays “STANDBY” At initial start up the various warning messages will appear here (see Section 3.4.3 below). Instrument is in STANDBY mode. STATUS LEDs Active Green OFF Auto Yellow OFF Fault Red BLINKING Unit is operating in STANDBY mode. This LED glows green when the instrument is actively producing calibration gas. This LED only glows when the calibrator is performing an automatic calibration sequence. The calibrator is warming up and therefore many of its subsystems are not yet operating within their optimum ranges. Various warning messages will appear. 3.4.3. WARNING MESSAGES Because internal temperatures and other conditions may be outside be specified limits during the calibrator’s warm-up period, the software will suppress most warning conditions for 30 minutes after power up. If warning messages persist after the 30 minutes warm up period is over, investigate their cause using the troubleshooting guidelines in Chapter 11 of this manual. To view and clear warning messages, press: STANDBY Suppresses the warning messages TEST GEN STBY SEQ MSG CLR SETUP STANDBY TEST SYSTEM RESET GEN STBY SEQ MSG CLR SETUP STANDBY TEST ANALOG CAL WARNING TEST Press CLR to clear the current message. If more than one warning is active, the next message will take its place. CLR SETUP STANDBY <TST MSG returns the active warnings to the message field. SYSTEM RESET GEN STBY SEQ MSG CLR SETUP SYSTEM Once the last warning has been cleared, the MESSAGE FIELD will return to displaying the currently selected TEST FUNCTION and value. SYSTEM RESET ACT =STANDBY TST> GEN STBY SEQ SETUP NOTE: If a warning message persists after several attempts to clear it, the message may indicate a real problem and not an artifact of the warm-up period Table 3-5 lists brief descriptions of the warning messages that may occur during start up. 22 05744 Rev B TELEDYNE API Getting Started M703E Calibrator Operator’s Manual Table 3-5: Possible Warning Messages at Start-Up MESSAGE ANALOG CAL WARNING CONFIG INITIALIZED DATA INITIALIZED The calibrator’s A/D converter or at least one analog input channel has not been calibrated. Stored Configuration information has been reset to the factory settings or has been erased. The calibrator’s data storage was erased. FRONT PANEL WARN The firmware is unable to communicate with the front panel. LAMP DRIVER WARN The firmware is unable to communicate with either the O3 generator or photometer lamp I2C driver chips. O3 GEN LAMP TEMP WARNING The O3 generator lamp temperature is outside of allowable limits. O3 GEN REFERENCE WARNING The O3 generator’s reference detector has dropped below the minimum allowable limit. O3 PUMP WARNING The pump associated with the O3 photometer has failed to turn on. PHOTO LAMP TEMP WARNING The photometer lamp temperature is outside of allowable limits. PHOTO REFERENCE WARNING The photometer reference reading is outside of allowable limits. REAR BOARD NOT DET RELAY BOARD WARN SYSTEM RESET 05744 Rev B MEANING The calibrator’s motherboard was not detected during power up. The firmware is unable to communicate with the calibrator’s relay board. The calibrator has been turned off and on or the CPU was reset. 23 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.4.4. FUNCTIONAL CHECK 7. After the calibrator’s components have warmed up for at least 30 minutes, verify that the software properly supports any hardware options that are installed. 8. Check to make sure that the calibrator is functioning within allowable operating parameters. Appendix C includes a list of test functions viewable from the calibrator’s front panel as well as their expected values. These functions are also useful tools for diagnosing problems with your calibrator (see Section7.5.2). The enclosed Final Test and Validation Data sheet (part number 05760) lists these values before the instrument left the factory. To view the current values of these parameters press the following key sequence on the calibrator’s front panel. Remember until the unit has completed its warm up these parameters may not have stabilized. STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ2 MSG CLR1 SETUP Toggle <TST TST> keys to scroll through list of functions 1 Only appears when warning messages are active. 2 Only appears when an one or more calibration sequences are programmed into the calibrator’s memory. ACT=GENERATE [Value] PPB O3 TARG=GENERATE [Value] PPB O3 OUTPUT FLOW=[Value] LPM REG PRESSURE=[Value] PSIG BOX TEMP=[Value]ºC O3 GEN REF=[Value] MV O3 GEN DRIVE=[Value] MV O3 LAMP TEMP=[Value]ºC PHOTO MEASURE[Value] MV PHOTO FLOW=[Value] LPM PHOTO LAMP TEMP=[Value]ºC PHOTO SPRESS=[Value] IN-HG-A PHOTO STEMP=[Value]ºC PHOTO SLOPE=[Value] PHOTO OFFSET=[Value] PPB PHOTO STABIL=[Value] PPB TEST=[Value]MV TIME=[HH:MM:SS] 9. If your calibrator has an Ethernet card (Option 63) installed and your network is running a dynamic host configuration protocol (DHCP) software package, the Ethernet option will automatically configure its interface with your LAN. However, it is a good idea to check these settings to make sure that the DHCP has successfully downloaded the appropriate network settings from your network server (See Section 7.5.2). If your network is not running DHCP, you will have to configure the calibrator’s interface manually (See Section 7.5.2. 24 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Getting Started 3.4.5. OPERATING MODES FOR THE O3 GENERATOR The O3 generator can be set to operate in three different modes: 3.4.5.1. CNST (CONSTANT) In this mode, the O3 output of the generator is based on a single, constant, drive voltage. There is no Feedback loop control by the M703E’s CPU in this mode. 3.4.5.2. REF (REFERENCE) The O3 control loop will use the reference detector’s measurement of the O3 generator’s UV lamp as input. This mode does not use the photometer to control the ozone generator. 3.4.5.3. BNCH (BENCH) The O3 concentration control loop will use the photometer’s O3 measurement as input. THIS IS THE DEFAULT AND MOST COMMON MODE OF OPERATION. This setting will be the default mode of the M703E calibrator and will be mused whenever the calibrator is using the GENERATE AUTO command or the GENERATE sequence step to create a calibration mixture. When either the GENERATE MAN command or the MANUAL sequence step is active, the local O3 generator mode (chosen during when the command/step is programmed) will take precedence. 3.4.6. SETTING THE O3 GENERATOR MODE To select a default O3 generator mode, press: 05744 Rev B 25 TELEDYNE API Getting Started M703E Calibrator Operator’s Manual 3.4.7. SETTING THE M703E’S OUTPUT FLOW RATE The output flow rate of the M703E should be adjusted to match the gas flow requirements of the analyzers connected to the output manifold. NOTE The minimum total flow should equal the sum of the flow requirements of all of the instruments to which the M703E will be supplying calibration gas plus 1 LPM excess flow. Example: If the M703E is will be expected to supply calibration gas mixtures simultaneously to two analyzers each requiring 0.8 LPM , the proper Total Flow output should be set at a minimum of: (0.8 + 0.8) + 1.0= 2.6 LPM To set the output flow: 1. Open the front panel of the calibrator down by releasing the two snap-in fasteners at the top of the front panel. 2. Pull out the regulator knob and adjust the regulator until the desired flow is achieved. The front panel of the M703E displays the approximate output flow based on the measured regulator pressure, but this flow should be verified with an independent calibrated flow meter attached to the on of the CAL GAS outlets on the back of the instrument (see Figure 3-2). 3. Push the regulator knob back in to lock. 4. Close the front panel. Pressure Regulator Adjustment Knob Figure 3-10: Location of Pressure Regulator Adjustment Knob USER NOTES: 26 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Frequently Asked Questions and Glossary 4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY 4.1. FAQ’S The following list is a list from the T-API Customer Service Department of the 10 most commonly asked questions relating to the Model 703E Photometric Calibrator. Q: My ozone ACT =XXXX, why? A: Look at the Photo Ref/Meas readings from the photometer UV lamp detector are most likely too low and need to be adjusted. See Section 10.5 Q: When I generate ozone, it takes a long time to settle out or it fluctuates around the target concentration until finally stabilizing. A: Perform an O3 Gen Calibration. See Section 8.2. Q: Why does the ENTR key sometimes disappear on the front panel display? A: Sometimes the ENTR key will disappear if you select a setting that is invalid or out of the allowable range for that parameter, such as trying to set the 24-hour clock to 25:00:00. Once you adjust the setting to an allowable value, the ENTR key will re-appear. Q: How do I make the RS-232 Interface Work? A: See Chapter 7 Q: When should I change the sintered filter(s) in the calibrators flow control(s) and how do I change them? A: The sintered filters do not require regular replacement. Should one require replacement as part of a troubleshooting or repair exercise, see Section 11.8.1. Q: How often should I rebuild the photometer pump on my calibrator? A: The photometer pump has been designed for longer service life than standard diaphragm pumps. When the pump wears out, the entire pump must be replaced. Q: How long do the UV lamps of the O3 generator and photometer last? A: The typical lifetime is about 2-3 years. 4.2. GLOSSARY Acronym – A short form or abbreviation for a longer term. Often artificially made up of the first letters of the phrase’s words. APICOM – Name of a remote control program offered by Teledyne-API to its customers ASSY - Acronym for Assembly. cm3 – metric abbreviation for cubic centimeter. Same as the obsolete abbreviation “cc”. DIAG - Acronym for diagnostics, the diagnostic menu or settings of the system DHCP: acronym for dynamic host configuration protocol. A protocol used by LAN or Internet servers that automatically sets up the interface protocols between themselves and any other addressable device connected to the network. 05744 Rev B 27 TELEDYNE API Frequently Asked Questions and Glossary M703E Calibrator Operator’s Manual DOC – Acronym for Disk On Chip, the system’s central storage area for system operating system, firmware and data. This is a solid-state device without mechanical, moving parts that acts as a computer hard disk drive under DOS with disk drive label “C”. DOC chips come with 8 mb space in the E-series system standard configuration but are available in larger sizes DOS - Disk Operating System. The E-series systems use DR DOS EEPROM - also referred to as a FLASH chip. FEP - Acronym for Fluorinated Ethylene Propylene polymer, one of the polymers that du Pont markets as Teflon® (along with PFA and PTFE). FLASH - flash memory is non-volatile, solid-state memory. I2C bus – read: I-square-C bus. A serial, clocked serial bus for communication between individual system components IC – Acronym for Integrated Circuit, a modern, semi-conductor circuit that can contain many basic components such as resistors, transistors, capacitors etc in a miniaturized package used in electronic assemblies. iDAS - Acronym for Internal Data Acquisition System, previously referred to as DAS. LAN - Acronym for local area network. LED - Acronym for Light Emitting Diode. LPM – Acronym for liters per minute MFC – Acronym for “mass flow controller”. MOLAR MASS – The molar mass is the mass, expressed in grams, of one mole of a specific substance. Conversely, one mole is the amount of the substance needed for the molar mass to be the same number in grams as the atomic mass of that substance. EXAMPLE: The atomic weight of Carbon is 12 therefore the molar mass of Carbon is 12 grams, conversely, one mole of carbon equals the amount of carbon atoms that weighs 12 grams. Atomic weights can be found on any Periodic Table of Elements PCA - Acronym for Printed Circuit Assembly, this is the PCB with electronic components installed and ready to use PCB - Acronym for printed circuit board, the bare circuit board without components PLC – Acronym for programmable logic controller, a device that is used to control instruments based on a logic level signal coming from the system PFA – Acronym for Per-Fluoro-Alkoxy, an inert polymer. One of the polymers that du Pont markets as Teflon® (along with FEP and PTFE). PTFE – Acronym for Poly-Tetra-Fluoro-Ethylene, a very inert polymer material used to handle gases that may react on other surfaces. One of the polymers that du Pont markets as Teflon® (along with FEP and PFA). PVC – Acronym for Poly Vinyl Chloride. RS-232 - An electronic communication protocol of a serial communications port RS-485 - An electronic communication protocol of a serial communications port SLPM – Acronym for standard liters per minute; liters per minute of a gas at standard temperature and pressure TCP/IP - Acronym for Transfer Control Protocol / Internet Protocol, the standard communications protocol for Ethernet devices and the Internet VARS - Acronym for variables, the variables menu or settings of the system USER NOTES: 28 05744 Rev B TELEDYNE API Optional Hardware and Software M703E Dynamic Dilution Calibrator Operator’s Manual 5. OPTIONAL HARDWARE AND SOFTWARE This includes a brief description of the hardware and software options available for the M703E Photometric Calibrator. For assistance with ordering these options, please contact the Sales department of Teledyne – Advanced Pollution Instruments at: TOLL-FREE: FAX: TEL: E-MAIL: WEB SITE: 800-324-5190 858-657-9816 858-657-9800 [email protected] www.teledyne-api.com 5.1. CARRYING STRAP HANDLE (OPT 29) The chassis of the M703E calibrator allows to attach a strap handle for carrying the instrument (Figure 5-). The handle is located on the right side and pulls out to accommodate a hand for transport. When pushed in, the handle is nearly flush with the chassis, only protruding out about 9 mm (3/8”). Figure 5-1: M703E with Carrying Strap Handle and Rack Mount Brackets Installing the strap handle prevents the use of the rack mount slides, although the rack mount brackets, Option 21, can still be used. CAUTION A FULLY LOADED M703E WITH BOTH THE O3 GENERATOR AND PHOTOMETER OPTIONS INSTALLED WEIGHS ABOUT 16.3 KG (36 POUNDS). TO AVOID PERSONAL INJURY WE RECOMMEND TWO PERSONS LIFT AND CARRY THE CALIBRATOR. MAKE SURE TO DISCONNECT ALL CABLES AND TUBING FROM THE CALIBRATOR BEFORE CARRYING IT. 05744 Rev B 29 TELEDYNE API Optional Hardware and Software M703E Dynamic Dilution Calibrator Operator’s Manual 5.2. COMMUNICATION OPTIONS 5.2.1. RS232 MODEM CABLES (OPTS 60 AND 60A) The analyzer can have come standard with a shielded, straight-through DB-9F to DB-9F cable of about 1.8 m length, which should fit most computers of recent build. This cable can be ordered as Option 60. Option 60A consists of a shielded, straight-through serial cable of about 1.8 m length to connect the calibrator’s COM1 port to a computer, a code activated switch or any other communications device that is equipped with a DB-25 female connector. The cable is terminated with one DB-9 female connector and one DB-25 male connector. The DB-9 connector fits the calibrator’s RS-232 port. 5.2.2. ETHERNET CABLE (OPT 60B) Option 60B consists of a 7-foot long, CAT-5 network cable, terminated at both ends with standard RJ-45 connectors. This cable is used to connect the M703E to any standard ETHERNET socket. 5.2.3. RS-232 MULTIDROP (OPT 62) The multidrop option is used with any of the RS-232 serial ports to enable communications of up to eight calibrators with the host computer over a chain of RS-232 cables via the instruments COM1 Port. It is subject to the distance limitations of the RS 232 standard. Rear Panel CPU Card (as seen from inside) Multidrop Card Figure 5-1: M703E Multidrop Card The option consists of a small printed circuit assembly, which plugs into to the calibrator’s CPU card (see Figure 5-6). It is connected to the RS-232 and COM2 DB9 connectors on the instrument’s back panel via a cable to the motherboard. One option 62 is required for each calibrator along with one 6’ straight-through, DB9 male DB9 Female cable (P/N WR0000101). 30 05744 Rev B TELEDYNE API Optional Hardware and Software M703E Dynamic Dilution Calibrator Operator’s Manual 5.2.4. ETHERNET (OPT 63) The ETHERNET option allows the calibrator to be connected to any Ethernet local area network (LAN) running TCP/IP. The local area network must have routers capable of operating at 10BaseT. If Internet access is available through the LAN, this option also allows communication with the instrument over the public Internet. Maximum communication speed is limited by the RS-232 port to 115.2 kBaud. When installed, this option is electronically connected to the instrument’s COM2 serial port making that port no longer available for RS-232/RS-485 communications. The option consists of a Teledyne Instruments designed Ethernet card (see Figures 5-7 and 5-8), and a 7-foot long CAT-5 network cable, terminated at both ends with standard RJ-45 connectors. Figure 5-2: Ethernet Card M703E Ethernet Card CPU Card Rear Panel (as seen from inside) Female RJ-45 Connector LNK LED ACT LED TxD LED RxD LED RS-232 Connector To Motherboard Interior View Figure 5-3: Exterior View M703E Rear Panel with Ethernet Installed For more information on setting up and using this option, see Section7.5 05744 Rev B 31 TELEDYNE API Optional Hardware and Software M703E Dynamic Dilution Calibrator Operator’s Manual 5.2.5. ETHERNET + MULTIDROP (OPT 64) This option allows the instrument to communicate on both RS-232 and ETHERNET networks simultaneously. It includes the following: RS232 MODEM CABLES (OPT 60A) ETHERNET CABLE (OPT 60B) RS-232 MULTIDROP (OPT 62) ETHERNET (OPT 63 5.3. ADDITIONAL MANUAL (OPT 70) Additional copies of the printed user’s manual can be purchased from the factory. Please specify the serial number of your calibrator so that we can match the manual version. This operator’s manual is also available on CD. The electronic document is stored in Adobe Systems Inc. Portable Document Format (PDF) and is viewable with Adobe Acrobat Reader® software, which can be downloaded for free at http://www.adobe.com/ The electronic version of this manual can also be downloaded free at http://www.teledyne-api.com/manuals/. Note that the online version is optimized for fast download and may not print with the same quality as the manual on CD. 5.4. EXTENDED WARRANTY (OPT 92) An extended, two-year warranty is available for the M703E calibrator. This option must be specified upon ordering the calibrator. 5.5. NIST TRACEABLE, PRIMARY STANDARD CERTIFICATION The Model 703E can be used as a Primary Ozone Standard. For this application the performance of the M703E Photometric Calibrator calibrated to Standard Reference Photometer (SRP) Calibrators ordered with this option are verified and validated in accordance with the procedures prescribed by the U.S. Environmental Protection Agency (EPA) under Title 40 of the Code of Federal Regulations, Part 50, Appendix D (40 CFR Part 50). An NIST traceable Certificate of Calibration and accompanies the instrument. USER NOTES: 32 05744 Rev B M703E Dynamic Dilution Calibrator Operator’s Manual TELEDYNE API OPERATING INSTRUCTIONS SECTION II – OPERATING INSTRUCTIONS 05744 Rev B 33 TELEDYNE API OPERATING INSTRUCTIONS M703E Dynamic Dilution Calibrator Operator’s Manual USER NOTES: 34 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6. OPERATING THE M703E CALIBRATOR The M703E calibrator is a computer-controlled calibrator with a dynamic menu interface for easy and yet powerful and flexible operation. All major operations are controlled from the front panel display and keyboard through these user-friendly menus. To assist in navigating the system’s software, a series of menu trees can be found in Appendix A of this manual. NOTE The flowcharts in this chapter depict the manner in which the front panel display/keyboard interface is used to operate the M703E Photometric Calibrator. They depict typical representations of the display during the various operations being described. They are not intended to be exact and may differ slightly from the actual display of your system. NOTE When editing values in the software, the ENTR key may disappear if you select a value that is invalid or out of the allowable range for that parameter (e.g. such as trying to set the 24-hour clock to 25:00:00). Once you adjust the setting to an allowable value, the ENTR key will re-appear. 05744 Rev B 35 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.1. TEST FUNCTIONS A variety of TEST FUNCTIONS are available for viewing at the front panel whenever the calibrator is at the MAIN MENU. These measurements provide information about the present operating status of the calibrator and are useful during troubleshooting (see Chapter 11). Table 6-1 lists the available TEST functions. To view these TEST functions, press <TST or TST> from the main menu and the Test Functions will scroll at the top center of the display. Table 6-1: TEST MEASUREMENT ACT=GENERATE XX PPB O3 TARG=GENERATE XX PPB O3 DESCRIPTION Actual concentration being generated, computed from real-time inputs. Target concentration to generate. OUTPUT FLOW=X.XXX LPM Output flow rate (computed from regulator pressure). REG PRESSURE=XX.X PSIG Regulator pressure. BOX TEMP=XX.X ºC O3 GEN REF=XXXX.X MV Internal chassis temperature. O3 generator reference detector reading. O3 GEN DRIVE=XXXX.X MV O3 generator lamp drive output. O3 LAMP TEMP=XX.X ºC O3 generator lamp temperature. PHOTO MEASURE=XXXX.X MV Photometer detector measure reading. PHOTO REFERENCE=XXXX.X MV Photometer detector reference reading. PHOTO FLOW=X.XXX LPM Photometer sample flow rate. PHOTO LAMP TEMP=XX.X ºC Photometer lamp temperature. PHOTO SPRESS=XX.X IN-HG-A Photometer sample pressure. PHOTO STEMP=XX.X ºC 36 Test Functions Defined Photometer sample temperature. PHOTO SLOPE=X.XXX Photometer slope computed during zero/span bench calibration. PHOTO OFFSET=X.X PPB Photometer offset computed during zero/span bench calibration. PHOTO STABIL=X.X PPB Photometer concentration stability (standard deviation of 25 bench concentration samples taken 10 seconds apart). TEST=XXXX.X MV Value output to TEST_OUTPUT analog output, selected with TEST_CHAN_ID variable. TIME=HH:MM:SS Current instrument time of day clock. (24 hour format) 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.2. OVERVIEW OF OPERATING MODES The M703E calibrator software has a variety of operating modes. Most commonly, the calibrator will be operating in STANDBY mode. In this mode, the calibrator and all of its subsystems are inactive although TEST functions and WARNING messages are still updated can be examined via the front panel. The second most important operating mode is SETUP mode. This mode is used for performing certain configuration operations, such as programming the concentration of source gases, setting up automatic calibration sequences and configuring the analog / digital inputs and outputs. The SET UP mode is also used for accessing various diagnostic tests and functions during troubleshooting. Mode Field STANDBY ACT =STANDBY <TST TST> GEN STBY GENERATE Key SEQ SETUP STANDBY Key Figure 6-1: Front Panel Display The mode field of the front panel display indicates to the user which operating mode the unit is currently running. Besides STANDBY and SETUP, other modes the calibrator can be operated in are: Table 6-2: Calibrator Operating Modes MODE MEANING DIAG One of the calibrator’s diagnostic modes is being utilized. When those diagnostic functions that have the greatest potential to conflict with generating concentrations are active, the instrument is automatically placed into standby mode. GENERATE In this mode, the instrument is engaged in producing calibration gas. SETUP3 STANDBY 3 05744 Rev B SETUP mode is being used to configure the calibrator. The calibrator is not actively generating gas. The revision of the Teledyne Instruments software installed in this calibrator will be displayed following the word SETUP. E.g. “SETUP B.4” 37 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.3. STANDBY MODE When the M703E Photometric Calibrator is in standby mode, it is at rest. Some functions under the SETUP MORE DIAG submenu, those which conflict with accurate creation of calibration gas mixtures (e.g. ANALOG OUTPUT STEP TEST) automatically place the calibrator into STANDBY mode when activated NOTE The M703E calibrator should always be placed in STANDBY mode when not needed to produce calibration gas. This can be done manually by pressing the STBY button that appears when the calibrator’s display is showing the top-level menu (see Figure 6-1). When programming a calibration sequences the STANDBY step should always be inserted at the end of the sequence. 38 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator 6.4. GENERAL INFORMATION ABOUT THE GENERATE MODE The GENERATE mode is the mode of operation where the M703E is actively producing calibration gas, either zero or some specified concentration of ozone. In the GENERATE mode the Zero Air Pump (if enabled) and Photometer Pump are turned on. 6.4.1. GENERATE AUTO: Basic Generation of Calibration Gas This is the simplest procedure for generating calibration gas mixtures. To generate calibration gas, press The M703E will now enter GENERATE mode. 05744 Rev B 39 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5. AUTOMATIC CALIBRATION SEQUENCES The M703E calibrator can be set up to perform automatic calibration sequences of multiple steps. These sequences can perform all of the calibration operations available for manual operation and can be set up to be triggered by using the front panel buttons, the M703E’s internal timer, the external digital control inputs, the RS232 interface, via the optional Ethernet interface or even as sub-processes in another sequence. 6.5.1. SETUP SEQ: PROGRAMMING CALIBRATION SEQUENCES A sequence is a database of single or multiple steps where each single step is an instruction that causes the instrument to perform an operation. These steps are grouped under a user defined SEQUENCE NAME. For each sequence, seven attributes must be programmed. They are: Table 6-3: Automatic Calibration SEQUENCE Set Up Attributes ATTRIBUTE NAME DESCRIPTION NAME Allows the user to create a text string of up to 10 characters identifying the sequence. Number of times, between 0 and 100, to execute the same sequence. A value of 0 (zero) causes the sequence to execute indefinitely. REPEAT COUNT CC INPUT Specifies which of the M703E’s Digital Control Inputs will initiate the sequence. CC OUTPUT Specifies which of the M703E’s Digital Control Outputs will be set when the sequence is active. TIMER ENABLE Enables or disables an internal automatic timer that can initiate sequences using the M703E’s built in clock. A series of submenus for programming the activities and instructions that make up the calibration sequence. STEPS Allows the user to select the reporting style the calibrator uses to report the progress of the sequences , on the front panels display, as it runs PROGRESS MODE The types of instruction steps available for creating calibration sequences are: Table 6-4: Calibration SEQUENCE Step Instruction INSTRUCTION NAME DESCRIPTION GENERATE Puts the instrument into GENERATE mode. Similar in operation and effect to the GENERATE AUTO function used at the front panel. DURATION Adds a period of time between the previous instruction and the next EXECSEQ Calls another sequence to be executed at this time. The calling sequence will resume running when the called sequence is completed. Up to 5 levels of nested sequences can be programmed. SETCCOUTPUT Allows the sequence to activate the M703E’s digital control outputs. Similar to the CC OUPUT attribute, but can be set and reset by individual steps. NOTE It is generally a good idea to end each calibration sequence with an instruction to return the instrument to STANDBY mode. 40 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator To create a sequence, use the instructions in the following sections to name the sequence, set it associated parameters and define the steps to be included. 6.5.1.1. Activating a Sequence from the M703E Front Panel To activate an already programmed sequence from the front panel, press: 05744 Rev B 41 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.1.2. Naming a Sequence The first step of creating a calibration sequence is to assign it a name. The name can be up to 10 characters and can be comprised of any alpha character (A to Z), and numeral (0 to 9) or the underscore character (“_“). To assign a name to a sequence, press, STANDBY Make sure that the M703E is in standby mode. <TST ACT CAL=0.000 LPM TST> GEN STBY SEQ SETUP X.X GAS SETUP PRIMARY SETUP MENU SEQ CFG SETUP X.X CLK PASS MORE EXIT SEQUENCE CONFIGURATION EDIT PRINT EXIT This display only appears if there are no sequences currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF SEQUENCES INS SETUP X.X PREV NEXT EXIT 1) SEQ [NAME], [X] STEPS INS DEL EDIT PRNT EXIT SETUP X.X SET> Deletes the sequence shown in the message field NAME:0 EDIT EXIT Edits the sequence shown in the message field Scrolls back and forth between existing sequences SETUP X.X Moves the cursor one character left or right. <CH CH> NAME:[0] INS DEL [0] ENTER EXIT EXIT discards the new NAME ENTR accepts the new NAME Inserts a new a character at the cursor location. 42 PRNT Deletes a character at the cursor location. Toggle this key to cycle through the range of numerals and available characters: (“A – Z”; “0 – 9” & “ _ ”) 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.1.3. Setting the Repeat Count for a Sequence The sequence can be set to repeat a certain number of times, from 1 to 100. It can also be set to repeat indefinitely by inputting a zero (0) into the REPEAT COUNTER. To set the REPEAT COUNTER, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ CFG SETUP X.X CLK PASS MORE EXIT SEQUENCE CONFIGURATION EDIT PRINT EXIT This display only appears if there are no sequences currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF SEQUENCES INS SETUP X.X PREV NEXT PRNT EXIT 1) SEQ [NAME], [X] STEPS INS DEL EDIT PRNT EXIT SETUP X.X NAME:0 SET> Deletes the sequence shown in the message field EDIT EXIT Edits the sequence shown in the message field Continue pressing SET> until ... Scrolls back and forth between existing sequences SETUP X.X <SET SET> SETUP X.X 0 0 REPEAT COUNT:1 EDIT EXIT NAME:[0] 1 ENTER EXIT EXIT discards the new NAME Toggle these keys to set the repeat count from 1 to 100. Enter “0” to cause the sequence to loop indefinitely 05744 Rev B ENTR accepts the new NAME 43 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.1.4. Using the M703E’s Internal Clock to Trigger Sequences Sequences can be set to trigger based on the M703E’s internal clock. The sequence can be set up to start at a predetermined date and time. It can also be set to repeat after a predetermined delay time. So activate and sequence timer, press: 44 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To specify a starting time for the sequence, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ CFG SETUP X.X CLK PASS MORE EXIT SEQUENCE CONFIGURATION EDIT PRINT EXIT This display only appears if there are no sequences currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF SEQUENCES INS SETUP X.X PREV NEXT INS DEL EDIT PRNT EXIT EXIT SETUP X.X NAME:0 SET> Deletes the sequence shown in the message field EDIT EXIT Edits the sequence shown in the message field Scrolls back and forth between existing sequences Continue pressing SET> until ... SETUP X.X <SET SET> SETUP X.X <SET SET> SETUP X.X 0 Toggle these keys to enter starting day, month and year. 1 DAY 1 Toggle these keys to enter the starting time TIMER ENABLE:ENABLED EDIT EXIT TIMER START: 01-JAN-06 00:00 EDIT EXIT TIMER START: 01-JAN-06 JAN 0 6 00:00 ENTR EXIT TIME: 12:00 2 HOUR :0 0 MINUTE EXIT discards the new setting ENTR accepts the new setting MONTH YEAR SYSTEM 05744 Rev B PRNT 1) SEQ [NAME], [X] STEPS ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 45 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To set the delta timer, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ CFG SETUP X.X CLK PASS MORE EXIT SEQUENCE CONFIGURATION EDIT PRINT EXIT This display only appears if there are no sequences currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF SEQUENCES INS SETUP X.X PREV NEXT PRNT EXIT 1) SEQ [NAME], [X] STEPS INS DEL EDIT PRNT EXIT SETUP X.X NAME:0 SET> Deletes the sequence shown in the message field EDIT EXIT Edits the sequence shown in the message field Scrolls back and forth between existing sequences Continue pressing SET> until ... SETUP X.X <SET SET> SETUP X.X 0 0 TIMER DELTA: 001:00:00 EDIT EXIT TIMER DELTA: 0 Days 0 ENTR EXIT Toggle these keys to enter number of days to wait between before running sequence again. ENTR accepts the new setting SYSTEM 1 Toggle these keys to enter the starting time 46 EXIT discards the new setting TIMER DELTA 00:00 2 HOUR :0 0 MINUTE ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator 6.5.1.5. Setting Up Control Inputs for a Sequence The M703E calibrator’ control inputs allow the entire sequence to be triggered from an external source. This feature allows the calibrator to operate in a slave mode so that external control sources, such as a data logger can initiate the calibration sequences. Each of the M703E calibrator’s control outputs, located on the back of the instrument (see Figure 3-2) 12 separate ON/OFF switches assigned to separate calibration sequences or; A 12-bit wide bus allowing the user to define activation codes for up to 4095 separate calibration sequences. To assign a CC INPUT pattern / code to a particular sequence, press. 05744 Rev B 47 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.1.6. Setting Up Control Outputs for a Sequence The M703E calibrator’s control outputs allow the entire sequence to be triggered from an external source. This feature allows the calibrator to control devices that accept logic-level digital inputs, such as programmable logic controllers (PLC’s), dataloggers, or digital relays/valve drivers. They can be used as: 12 separate ON/OFF switches assigned to separate calibration sequences, or; A 12-bit wide bus allowing the user to define activation codes for up to 4095 separate calibration sequences. They can be set to: Be active whenever a particular calibration sequence is operating, or; Activate/deactivate as individual steps within a calibration sequence are run See Section 6.5.2.5). To assign a CC OUTPUT pattern / code to a particular sequence, press. STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ CFG SETUP X.X CLK PASS MORE EXIT SEQUENCE CONFIGURATION EDIT PRINT EXIT This display only appears if there are no sequences currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF SEQUENCES INS SETUP X.X PREV NEXT PRNT EXIT 1) SEQ [NAME], [X] STEPS INS DEL EDIT PRNT EXIT SETUP X.X NAME:0 SET> Deletes the sequence shown in the message field EDIT EXIT Edits the sequence shown in the message field Scrolls back and forth between existing sequences Continue pressing SET> until ... SETUP X.X <SET SET> SETUP X.X CC OUTPUT:DISABLED EDIT EXIT CC OUTPUT ENABLE:OFF OFF ENTER EXIT Toggle this key turn the CC input ON/OFF ENTR accepts the new setting SETUP X.X Moves the cursor one character left or right. EXIT discards the new setting <CH CH> CC OUTPUT:[0]00000000000 [0] ENTER EXIT Toggle this key to turn the selected bit ON/OFF (0 or 1). EXIT discards the new setting ENTR accepts the new setting Each bit shown on the display represents one of the control output pins located on the back of the M703E (see Figure 3-2), The left most bit is Bit 1, the next bit to the right, bit 2, progressing rightward to bit 12 (see Figure 3-10 for connector pin assignments) 48 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.1.7. Setting the PROGRESS Reporting Mode for the Sequences As sequences run, the M703E calibrator reports progress by displaying a message in the MODE field of the front panel display (See Figure 3-1). There are several types of report modes available Table 6-5: Sequence Progress Reporting Mode MODE DESCRIPTION STEP Shows the progress as the sequence name and step number. This is the traditional display. Example: “SO2_Test-2”. Shows the progress as a percent (0–100%) of the total sequence duration. Example: “SEQ 48%” PCT ELAP Shows the progress as days, hours, minutes and seconds elapsed, counting up from 0. Example (<1 day): “T+01:30:25” (i.e. 1 hour, 30 minutes, 25 seconds elapsed) Example (>=1 day): “T+1d30:25” (i.e. 1 day, 30 hours, 25 minutes elapsed) REM Shows the progress as days, hours, minutes, and seconds remaining, counting down to 0. Example (<1 day): “T–01:30:25” (i.e. 1 hour, 30 minutes, 25 seconds remaining) Example (>=1 day): “T–1d30:25” (i.e. 1 day, 30 hours, 25 minutes remaining) To select a PROGRESS report mode, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ CFG SETUP X.X CLK PASS MORE EXIT SEQUENCE CONFIGURATION EDIT PRINT EXIT This display only appears if there are no sequences currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF SEQUENCES INS SETUP X.X PREV NEXT PRNT EXIT 1) SEQ [NAME], [X] STEPS INS DEL EDIT PRNT EXIT SETUP X.X NAME:0 SET> Deletes the sequence shown in the message field EDIT EXIT Edits the sequence shown in the message field Scrolls back and forth between existing sequences Continue pressing SET> until ... STEPS Submenu SETUP X.X <SET SETUP X.X STEP PCT PROGRESS MODE:REM EDIT EXIT PROGRESS MODE:REM ELAP REM ENTR EXIT Use these keys to choose a PROGRESS MODE SETUP X.X <SET PROGRESS MODE:ELAP EDIT EXIT 8 05744 Rev B 49 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.2. ADDING SEQUENCE STEPS To insert an instruction step into a sequence, navigate to the INSERT STEP submenu by pressing: 50 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.2.1. The Generate Step This step operates and is programmed similarly to the GENERATE AUTO. At the end of the programming sequence, the M703E firmware will automatically insert a DURATION step that needs to be defined. To insert a GENERATE step into a sequence, press: Starting at the INSERT STEPS Submenu INSERT STEP Submenu SETUP X.X INSERT STEP: GENERATE PREV NEXT ENTR SETUP X.X GENERATE:ZERO ZERO ENTR SETUP X.X 0 0 SETUP X.X 0 Toggle these keys to set the target concentration. .0 0 EXIT GENERATE:0.0 PPB O3 0 .0 PPB O3 ENTR EXIT Toggle this key to switch between ZERO AIR and O3 modes. Toggle this key to to scroll through the available units of measure GENERATE:0.0 PPB O3 0 SETUP X.X 0 EXIT 0 PCT O3 ENTR EXIT EXIT discards the new target concentration ENTR accepts the new target concentration DURATION: 1.0 MIN 1 .0 ENTR EXIT Toggle these keys to set DURATION of this step SETUP X.X PREV NEXT 05744 Rev B 3) DURATION : 10.0 MIN INS DEL EDIT EXIT 51 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.2.2. The STANDBY Step The STANDBY step places the calibrator into STANDBY mode To insert a STANDBY step into a sequence, press: 6.5.2.3. The DURATION Step The duration step causes the M703E to continue performing whatever action was called for by the preceding step of the sequence. If that step put the instrument into STANDBY mode, the calibrator stays in STANDBY mode for the period specified by the DURATION step, If that step put the instrument into GENERATE mode, the will continue to GENERATE whatever calibration mixture was programmed into that step for the period specified by the DURATION step, To insert a DURATION step into a sequence, press: 52 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator 6.5.2.4. The EXECSEQ Step The EXECSEQ step allows the sequence to call another, already programmed sequence. This is a very powerful tool in that it allows the user to create a “toolbox” of often-used operations that can then be mixed and matched by an overhead sequence: To insert an EXECSEQ step into a sequence, press: 05744 Rev B 53 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.2.5. The CC OUTPUT Step This instruction causes the sequence to set or reset the M703E’s digital control outputs. It is very useful in situations where the control outputs are being used to trigger other devices that need to be turned off and on in synch with the operation of the calibrator as it progress through the sequence. To insert a CC OUTPUT step into a sequence, press: Starting at the STEPS Submenu INSERT STEP Submenu SETUP X.X INSERT STEP: GENERATE PREV NEXT ENTR EXIT Use the PREV and NEXT keys to scroll though the list of available instructions SETUP X.X INSERT STEP: PURGE ENTR SETUP X.X CC OUTPUT:DISABLED <SET SET> SETUP X.X EXIT EDIT EXIT CC OUTPUT ENABLE:OFF OFF ENTER EXIT Toggle this key turn the CC input ON/OFF ENTR accepts the new setting SETUP X.X Moves the cursor one character left or right. <CH CC OUTPUT:[0]00000000000 CH> [0] ENTER EXIT Toggle this key to turn the selected bit ON/OFF (0 or 1) SETUP X.X PREV NEXT 54 EXIT discards the new setting 2) SET CC OUTPUT 000100010110 INS DEL EDIT EXIT 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator 6.5.2.6. Deleting or Editing an Individual Step in a Sequence To delete or edit an individual step in an existing Sequence, press: 05744 Rev B 55 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.5.3. DELETING A SEQUENCE To delete a sequence from the M703E calibrator’s memory, press: STANDBY Make sure that the M703E is in standby mode. <TST SETUP TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY SEQ SETUP X.X PRIMARY SETUP MENU CFG CLK PASS MORE SEQUENCE CONFIGURATION EXIT EDIT PRINT SETUP X.X PREV NEXT EXIT 3) SEQ [NAME], [X] STEPS INS DEL EDIT PRNT EXIT Scrolls back and forth between existing sequences SETUP X.X YES DELETE SEQUENCES NO SEQUENCE DELETED SETUP X.X PREV NEXT 56 END OF SEQUENCES INS PRNT EXIT 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.6. SETUP CFG Pressing the CFG key displays the instrument’s configuration information. This display lists the calibrator model, serial number, firmware revision, software library revision, CPU type and other information. Use this information to identify the software and hardware when contacting customer service. Special instrument or software features or installed options may also be listed here. STANDBY <TST TST> GEN STBY SEQ SETUP X.X O3 Press NEXT of PREV to move back and forth through the following list of Configuration information: MODEL TYPE AND NUMBER PART NUMBER SERIAL NUMBER SOFTWARE REVISION LIBRARY REVISION iCHIP SOFTWARE REVISION (Only ACT =STANDBY SETUP MENU SEQ CFG SETUP X.X PREV NEXT SETUP CLK PASS MORE EXIT M703E Cailbrator EXIT Press exit at any time to return to the SETUP menu appears if INET option is installed) CPU TYPE & OS REVISION DATE FACTORY CONFIGURATION SAVED 05744 Rev B 57 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.7. SETUP CLK 6.7.1. SETTING THE INTERNAL CLOCK’S TIME AND DAY The M703E has a time of day clock that supports the DURATION step of the calibration sequence feature, time of day TEST function, and time stamps on most COM port messages. To set the clock’s time and day, press: STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SEQ SETUP PRIMARY SETUP MENU CFG SETUP X.X CLK PASS MORE TIME-OF-DAY CLOCK TIME DATE SETUP X.X 1 2 HOUR TIME: 12:00 :0 MINUTE SETUP X.X 2 2 0 0 ENTR EXIT 0 Toggle these keys to enter current hour 1 DATE: 01-JAN-05 JAN ENTR EXIT TIME DATE 0 5 DAY MONTH YEAR SETUP X.X SETUP X.X 58 EXIT SETUP X.X TIME: 22:30 :3 EXIT 1 8 ENTR EXIT Toggle these keys to enter current day, month and year. DATE: 18-JUN-05 JUN 0 5 TIME-OF-DAY CLOCK EXIT ENTR EXIT EXIT returns to SETUP X.X display 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator 6.7.2. ADJUSTING THE INTERNAL CLOCK’S SPEED In order to compensate for CPU clocks which run faster or slower, you can adjust a variable called CLOCK_ADJ to speed up or slow down the clock by a fixed amount every day. To change this variable, press: 05744 Rev B 59 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.8. SETUP PASS The M703E provides password protection of the calibration and setup functions to prevent unauthorized adjustments. When the passwords have been enabled in the PASS menu item, the system will prompt the user for a password anytime a password-protected function is requested. There are three levels of password protection, which correspond to operator, maintenance and configuration functions. Each level allows access to all of the functions in the previous level. Table 6-6: Password Levels PASSWORD LEVEL MENU ACCESS ALLOWED No password Operator All functions of the MAIN menu: TEST, GEN, initiate SEQ , MSG, CLR 101 Maintenance Access to Primary and Secondary Setup Menus except for VARS & DIAG 818 Configuration Secondary SETUP Submenus VARS and DIAG To enable or disable passwords, press: 60 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual Example: If all passwords are enabled, the following keypad sequence would be required to enter the VARS or DIAG submenus: STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 PRIMARY SETUP MENU SEQ SETUP X.X CFG CLK PASS MORE EXAMPLE: This password enables the SETUP mode SYSTEM 0 EXIT ENTER SETUP PASS:0 0 0 SYSTEM 8 EXIT SECONDARY SETUP MENU COMM VARS DIAG Press individual keys to set number SETUP ENTR EXIT ENTER SETUP PASS:0 1 8 ENTR EXIT M703E enters selected menu NOTE The instrument still prompts for a password when entering the VARS and DIAG menus, even if passwords are disabled, but it displays the default password (818) upon entering these menus. The user only has to press ENTR to access the password-protected menus but does not have to enter the required number code. 05744 Rev B 61 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9. SETUP DIAG TEST CHAN OUTPUT: USING THE TEST CHANNEL ANALOG OUTPUT The M703E calibrator comes equipped with one analog output. It can be set by the user to carry the current signal level of any one of the parameters listed in Table 6-8 and will output an analog VDC signal that rises and falls in relationship with the value of the parameter. Pin-outs for the analog output connector at the rear panel of the instrument are: ANALOG OUT + Figure 6-2: – M703E the TEST CHANNEL Connector 6.9.1. CONFIGURING THE TEST CHANNEL ANALOG OUTPUT 6.9.1.1. The Analog I/O Configuration Submenu. Table 6-7 lists the analog I/O functions that are available in the M703E calibrator. Table 6-7: DIAG - Analog I/O Functions SUB MENU AOUTS CALIBRATED: FUNCTION Shows the status of the analog output calibration (YES/NO) and initiates a calibration of all analog output channels. CAL_OUT_1: NOT USED ON THE M703E CAL_OUT_2 TEST OUTPUT Configures the 11 analog output: RANGE1: Selects the DCV full-scale value of the output. OVERRANGE: Turns the ± 5% over-range feature ON/OFF for this output channel. REC_OFS1: Sets a voltage offset (not available when RANGE is set to CURRent loop. AUTO_CAL1: Sets the channel for automatic or manual calibration 1 CALIBRATED : Performs the same calibration as AOUT CALIBRATED, but on this one channel only. AIN CALIBRATED 1 Shows the calibration status (YES/NO) and initiates a calibration of the analog to digital converter circuit on the motherboard. Changes to RANGE or REC_OFS require recalibration of this output. To configure the analyzer’s TEST CHANNEL, set the electronic signal type of each channel and calibrate the outputs. This consists of: 10. Choosing a TEST CHANNEL function to be output on the channel. 11. Selecting a signal level that matches the input requirements of the recording device attached to the channel. 12. Determining if the over-range feature is needed and turn it on or off accordingly. 13. Adding a bipolar recorder offset to the signal if required (Section6.9.1.5). 14. Calibrating the output channel. This can be done automatically or manually for each channel (see Sections 6.9.2). 62 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To access the analog I/O configuration sub menu, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ SETUP X.X CFG CLK PASS MORE SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X 8 Toggle these keys to enter the correct PASSWORD EXIT EXIT ENTER PASSWORD:818 1 8 DIAG ENTR EXIT SIGNAL I/O NEXT ENTR EXIT Continue pressing NEXT until ... AIO Configuration Submenu DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO ENTR A OUTS CALIBRATED: NO <SET SET> CAL DIAG AIO EXIT EXIT AIN CALIBRATED: NO <SET SET> CAL 05744 Rev B Not used in the M703E TEST_OUTPUT: 5V,OVR, NOCAL <SET SET> EDIT DIAG AIO EXIT CONC_OUT_2: 5V, OVR, NOCAL <SET SET> EDIT DIAG AIO EXIT CONC_OUT_1: 5V, OVR, NOCAL <SET SET> EDIT DIAG AIO EXIT EXIT 63 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.1.2. Selecting a Test Channel Function to Output The Test Functions available to be reported are: Table 6-8: Test Channels Functions Available on the M703E’s Analog Output TEST CHANNEL NONE DESCRIPTION ZERO FULL SCALE TEST CHANNEL IS TURNED OFF O3 PHOTO MEAS The raw output of the photometer during its measure cycle 0 mV 5000 mV* O3 PHOTO REF The raw output of the photometer during its reference cycle 0 mV 5000 mV* O3 GEN REF The raw output of the O3 generator’s reference detector 0 mV 5000 mV* OUTPUT FLOW The gas flow being output through the CAL GAS outlets on the back of the instrument 0 cm3/min 5,000 cm3/min REGULATOR PRESSURE The gas pressure measured by the O3 generator pressure sensor 0 PSIG 105 PSIG SAMPLE PRESSURE The pressure of gas in the photometer absorption tube 0 "Hg 40 "Hg-In-A SAMPLE FLOW The gas flow rate through the photometer 3 0 cm /min 1000 cc3/min SAMPLE TEMP The temperature of gas in the photometer absorption tube 0 C 70 C PHOTO LAMP TEMP The temperature of the photometer UV lamp 0 C 70 C O3 LAMP TEMP The temperature of the O3 generator’s UV lamp 0 mV 5000 mV CHASSIS TEMP The temperature inside the M703E’s chassis (same as BOX TEMP) 0 C 70 C O3 PHOTO CONC The current concentration of O3 being measured by the photometer. 0 C 1 ppm Once a function is selected, the instrument not only begins to output a signal on the analog output, but also adds TEST to the list of Test Functions viewable via the Front Panel Display. 64 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To activate the TEST Channel and select a function press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ SETUP X.X CFG CLK PASS MORE SECONDARY SETUP MENU COMM VAR DIAG SETUP X.X 8 EXIT EXIT ENTER PASSWORD 1 8 ENTR EXIT ENTR EXIT Toggle these keys to enter the correct PASSWORD DIAG SIGNAL I/O PREV NEXT Continue pressing NEXT until ... DIAG PREV NEXT DIAG PREV NEXT Toggle these keys to choose a TEST channel parameter DIAG PREV NEXT TEST CHANNEL OUTPUT ENTR EXIT TEST CHANNEL:NONE ENTR EXIT TEST CHANNEL:CHASSIS TEMP ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 05744 Rev B 65 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.1.3. TEST CHANNEL VOLTAGE RANGE Configuration In its standard configuration the analog outputs is set to output a 0 – 5 VDC signals. Several other output ranges are available (see Table 7-5). Each range has is usable from -5% to + 5% of the rated span. Table 6-9: Analog Output Voltage Range Min/Max RANGE SPAN 0-100 mVDC 0-1 VDC 0-5 VDC 0-10 VDC MINIMUM OUTPUT MAXIMUM OUTPUT -5 mVDC 105 mVDC -0.05 VDC 1.05 VDC -0.25 VDC 5.25 VDC -0.5 VDC 10.5 VDC The default offset for all ranges is 0 VDC. To change the output range, press, From the AIO CONFIGURATION SUBMENU (See Section 6.9.1.1) DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO SET> ENTR EXIT AOUTS CALIBRATED: NO CAL EXIT Continue pressing SET> until you reach the output to be configured DIAG AIO TEST_OUTPUT: 5V, OVR, NOCAL <SET SET> EDIT These keys set the signal level and type of the selected channel 66 DIAG AIO 0.1V EXIT TEST_OUTPUT: RANGE: 5V 1V 5V 10V ENTR EXIT Pressing ENTR records the new setting and returns to the previous menu. Pressing EXIT ignores the new setting and returns to the previous menu. 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator 6.9.1.4. Turning the TEST CHANNEL Over-Range Feature ON/OFF In its default configuration a ± 5% over-range is available on each of the M703E’s TEST CHANNEL output. This over-range can be disabled if your recording device is sensitive to excess voltage or current. To turn the over-range feature on or off, press: 05744 Rev B 67 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.1.5. Adding a Recorder Offset to the TEST CHANNEL Some analog signal recorders require that the zero signal be significantly different from the baseline of the recorder in order to record slightly negative readings from noise around the zero point. This can be achieved in the M703E by defining a zero offset, a small voltage (e.g., 10% of span). To add a zero offset to a specific analog output channel, press: 68 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.2. TEST CHANNEL CALIBRATION TEST CHANNEL calibration needs to be carried out on first startup of the analyzer (performed in the factory as part of the configuration process) or whenever re-calibration is required. The analog outputs can be calibrated automatically or adjusted manually. During automatic calibration, the analyzer tells the output circuitry to generate a zero mV signal and high-scale point signal (usually about 90% of chosen analog signal scale) then measures actual signal of the output. Any error at zero or high-scale is corrected with a slope and offset. Automatic calibration can be performed via the AOUTS CALIBRATION command, or by using the CAL button located inside TEST_CHANNEL submenu. By default, the analyzer is configured so that calibration of TEST CHANNEL can be initiated with the AOUTS CALIBRATION command. 6.9.2.1. Enabling or disabling the TEST CHANNEL Auto-Cal Feature To enable or disable the Auto-Cal feature for the TEST CHANNEL, press. From the AIO CONFIGURATION SUBMENU (See Section 6.9.1.1.) DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO SET> NOTE: ENTR EXIT AOUTS CALIBRATED: NO CAL EXIT Continue pressing SET> until you reach the output to be configured TEST CHANNELS configured for 0.1V full scale should always be calibrated manually. DIAG AIO TEST_OUTPUT: 5V, OVR, NOCAL <SET SET> EDIT DIAG AIO EXIT TEST_OUTPUT: RANGE: 5V SET> EDIT EXIT Continue pressing SET> until ... DIAG AIO TEST_OUTPUT: AUTO CAL.:ON <SET SET> EDIT Toggle this key to turn AUTO CAL ON or OFF DIAG AIO ON EXIT TEST_OUTPUT: AUTO CAL.:ON ENTR EXIT (OFF = manual calibration mode). DIAG AIO OFF 05744 Rev B ENTR accepts the new setting. EXIT ignores the new setting TEST_OUTPUT: AUTO CAL.:OFF ENTR EXIT 69 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.2.2. Automatic TEST CHANNEL Calibration To calibrate the outputs as a group with the AOUTS CALIBRATION command, press: NOTE Before performing this procedure, make sure that the AUTO CAL feature is turned OFF for CONC_OUT_1 and CONC_OUT_2, Make sure that the AUTO CAL feature is turned ON for the TEST CHANNEL (See Section 6.9.2.1) From the AIO CONFIGURATION SUBMENU (See Section 6.9.1.1.) DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO If any of the channels have not been calibrated ot if at least one channel has AUTO-CAL turned OFF, this message will read NO. CAL DIAG AIO EXIT NOT AUTO CAL. CONC_OUT_1 DIAG AIO DIAG AIO DIAG AIO EXIT AOUTS CALIBRATED: NO SET> Analyzer automatically calibrates all channels for which AUTO-CAL is turned ON ENTR This message appears when AUTO-CAL is Turned OFF for a channel NOT AUTO CAL. CONC_OUT_2 AUTO CALIBRATING TEST_OUTPUT AOUTS CALIBRATED: YES SET> CAL EXIT NOTE: Manual calibration should be used for the 0.1V range or in cases where the outputs must be closely matched to the characteristics of the recording device. 70 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating the M703E Calibrator To initiate an automatic calibration from inside the TEST CHANNEL submenu, press: 05744 Rev B 71 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.2.3. Manual Calibration of the TEST CHANNEL configured for Voltage Ranges For highest accuracy, the voltages of the analog outputs can be manually calibrated. NOTE: The menu for manually adjusting the analog output signal level will only appear if the AUTO-CAL feature is turned off for the channel being adjusted (see Section6.9.2.1) Calibration is performed with a voltmeter connected across the output terminals (See Figure 6-2) and by changing the actual output signal level using the front panel keys in 100, 10 or 1 count increments. V +DC Figure 6-3: Gnd Setup for Calibrating the TEST CHANNEL Table 6-10: Voltage Tolerances for the TEST CHANNEL Calibration 72 FULL SCALE ZERO TOLERANCE SPAN VOLTAGE SPAN TOLERANCE MINIMUM ADJUSTMENT (1 count) 0.1 VDC ±0.0005V 90 mV ±0.001V 0.02 mV 1 VDC ±0.001V 900 mV ±0.001V 0.24 mV 5 VDC ±0.002V 4500 mV ±0.003V 1.22 mV 10 VDC ±0.004V 4500 mV ±0.006V 2.44 mV 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To adjust the signal levels of an analog output channel manually, press: From the AIO CONFIGURATION SUBMENU (See Section 6.9.1.1.) DIAG ANALOG I/O CONFIGURATION PREV NEXT DIAG AIO SET> ENTR EXIT AOUTS CALIBRATED: NO CAL EXIT Continue pressing SET> until you reach the output to be configured DIAG AIO TEST_OUTPUT: 5V, OVR, NOCAL <SET SET> EDIT DIAG AIO EXIT TEST_OUTPUT: RANGE: 5V SET> EDIT EXIT Continue pressing SET> until ... DIAG AIO TEST_OUTPUT: CALIBRATED:NO <SET SET> CAL DIAG AIO These keys increase / decrease the analog output signal level (not the value on the display) by 100, 10 or 1 counts. Continue adjustments until the voltage measured at the output of the analyzer and/or the input of the recording device matches the value in the upper right hand corner of the display (within the tolerances listed in Table 6-10 TEST_OUTPUT: VOLT-Z: 0 mV U100 UP10 UP DIAG AIO These menu’s only appear if AUTO-CAL is turned OFF DOWN DN10 D100 ENTR EXIT TEST_OUTPUT: CALIBRATED: YES <SET SET> CAL 05744 Rev B DOWN DN10 D100 ENTR EXIT TEST_OUTPUT: VOLT-S: 4500 mV U100 UP10 UP DIAG AIO EXIT EXIT 73 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.9.3. AIN CALIBRATION This is the sub-menu calibrates the analyzer’s A-to-D conversion circuitry. This calibration should only be necessary after major repair such as a replacement of CPU, motherboard or power supplies. To perform an AIN CALIBRATION, press: 74 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.10. SETUP MORE VARS: INTERNAL VARIABLES (VARS) The M703E has several-user adjustable software variables, which define certain operational parameters. Usually, these variables are automatically set by the instrument’s firmware, but can be manually re-defined using the VARS menu. The following table lists all variables that are available within the 818 password protected level. See Appendix A2 for a detailed listing of all of the M703E variables that are accessible through the remote interface. Table 6-11: Variable Names (VARS) NO. VARIABLE 0 PHOTO_LAMP1,2 O3_GEN LAMP1,2 1 2 O3_CONC_RANGE ALLOWED VALUES DEFAULT VALUES Sets the photometer lamp temperature set point and warning limits. 0ºC and 100ºC 58ºC Warning limits Sets the O3 generator lamp temperature set point and warning limits. 0ºC and 100ºC Set the upper span point of the O3 concentration range for TEST CHANNEL analog signal O3_PHOTO_CONC. 0.1–20000 ppb DESCRIPTION 56ºC - 61ºC 48ºC Warning limits 43ºC - 53ºC 500 ppb O3 bench control flag. ON turns on the photometer pump and switches measure/reference valve only when the O3 mode is set for BNCH (See Section 3.4.5). ON/OFF 3 O3_PHOTO_BENCH_ONLY2 4 ZA_PUMP_ENAB2 5 STD_TEMP1 Sets the standard Temperature used in calculating O3 flow rates and concentrations. 0ºC and 100ºC 25ºC 6 STD PRESSURE1 Sets the standard pressure used in calculating O3 flow rates and concentrations. 29.92 in-Hg-A 15.00 – 50 .00 in-Hg-A CLOCK_ADJ Adjusts the speed of the analyzer’s clock. Choose the + sign if the clock is too slow, choose the - sign if the clock is too fast (See Section 6.7.2). -60 to +60 s/day Default=0 0 7 1 Internal zero air pump control. ON turns on internal zero air pump when generating ozone. ON/OFF OFF ON DO NOT ADJUST OR CHANGE these values unless instructed to by Teledyne Instruments’ customer service personnel. 2 Only available in calibrators with O3 photometer and generator options installed. NOTE: There is a 2-second latency period between when a VARS value is changed and the new value is stored into the analyzer’s memory. DO NOT turn the analyzer off during this period or the new setting will be lost. 05744 Rev B 75 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To access and navigate the VARS menu, use the following key sequence: Make sure that the M703E is in standby mode. STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SEQ SETUP X.X SETUP PRIMARY SETUP MENU CFG CLK PASS MORE SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X 8 1 EXIT EXIT ENTER PASSWORD 8 ENTR EXIT Toggle these keys to enter the correct PASSWORD SETUP X.X DO NOT CHANGE these settings unless specifically instructed to by Teledyne Instruments’ Customer Service personnel 0) O3_PHOTO_LAMP=58.0 DegC NEXT JUMP SETUP X.X ENTR accepts the new setting 1) O3_PHOT_LAMP=58.0 DegC PREV NEXT JUMP SETUP X.X In all cases: EXIT discards the new setting EDIT PRNT EXIT EDIT PRNT EXIT 2) O3_CONC_RANGE=500.0 PPB PREV NEXT JUMP EDIT PRNT EXIT SETUP X.X 0 SETUP X.X 0 ENTR EXIT Toggle this key turn this mode ON / OFF EDIT PRNT EXIT ZA_PUMP_ENAB=ON ON Toggle this key turn this mode ON / OFF EDIT PRNT EXIT 6) STD PRESS=29.92 In-Hg PREV NEXT JUMP PREV ENTR EXIT 5) STD_TEMP=25.0 DegC PREV NEXT JUMP SETUP X.X EXIT O3_PHOTO_BENCH_ONLY=OFF 0 SETUP X.X SETUP X.X ENTR 4) ZA_PUMP_ENAB=ON PREV NEXT JUMP these settings unless specifically instructed to by Teledyne Instruments’ Customer Service personnel .0 EDIT PRNT EXIT OFF DO NOT CHANGE 0 Toggle these keys to set the upper span point of the O3_PHOTO_CONC Test Channel signal SETUP X.X SETUP X.X 0 3) O3_PHOTO_BENCH_ONLY=OFF PREV NEXT JUMP SETUP X.X O3_CONC_RANGE=500.0 PPB 5 EDIT PRNT EXIT 7) CLOCK_ADJUST=0 Sec/Day JUMP EDIT ENTR EXIT SETUP X.X + 0 CLOCK_ADJUST=0 Sec/Day 0 ENTR EXIT Enter sign and number of seconds per day the clock gains (-) or loses(+) 76 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.11. OPERATING THE M703E CALIBRATOR AS AN O3 PHOTOMETER The M703E can easily be configured to measure an external source of ozone. 6.11.1. SET UP FOR OPERATING THE M703E AS AN O3 PHOTOMETER To convert the M703E from an O3 calibrator to and O3 photometer: 1. Remove the two loop-back tubing assemblies on the rear panel connected to the ‘PHOTO IN’ and ‘PHOTO REF IN’ fittings. 2. Connect the ozone source to be measured to the ‘PHOTO IN’ fitting. This gas must be supplied at atmospheric pressure. 3. Connect a reference gas (Zero Air) for the photometer to the ‘PHOTO REF IN.’ This gas must be supplied at atmospheric pressure. To avoid interference effects, the reference gas should be from the same source than is being used to feed the ozone generator that is being assayed. REFERENCE GAS SOURCE O3 SOURCE TO BE MEASURED PHOTOMETER INLET PHOTOMETER OUTLET Capped 1 PHOTOMETER ZERO IN PHOTOMETER ZERO OUT EXHAUST ZERO AIR IN EXHAUST line: Max Length=3 meters ( or 10 feet) VENT DRY AIR IN CAL GAS OUT Capped M703E Photometric O3 Calibrator 1 Minimum input gas flow for Photometer is 800 cc3/min Figure 6-4: 05744 Rev B Enclosure Wall CAL GAS OUT Set up for Using the M703E to Measure an External O3 Source 77 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual To use the M703E as a photometer, press: 78 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12. SETUP LVL: SETTING UP AND USING LEADS (DASIBI) OPERATING LEVELS 6.12.1. GENERAL INFORMATION ABOUT LEADS LEVELS The M703E calibrator can be equipped with a version of firmware that includes support for LEADS, a data collection and analysis system LEADS specifically designed for handling meteorological and environmental data particularly when there is a need to integrate data and control instrumentation from several different manufacturers. When an M703E calibrator is equipped with the optional LEADS software is used in conjunction with data loggers located central data analysis facility is possible to collect and buffer data between the various calibrators, analyzers and metrological equipment remotely located at an air monitoring station. Because LEADS was originally developed for use with TNRCC using Dasibi 5008 calibrators, the LEADS version of the M703E includes support for Dasibi “Dot” serial data commands and operational “LEVEL’s”. NOTE For more information on the LEADS system, please go to http://www.meteostar.com/. 6.12.2. DOT COMMANDS The Dasibi “Dot” commands form a text-based (ASCII) data protocol that is transmitted between a control computer (XENO data logger in this case) and a calibrator or ambient gas analyzer over an RS-232 connection. The details of the protocol are beyond the scope of this document, but in its simplest form the protocol is based on a two or three digit integer preceded by a control-A and a period (.) and then followed by a “!” and a two digit checksum. EXAMPLE: ^A.xxx!nn For further information on dot commands, please contact T-API customer service. An M703E equipped with LEADS software can be simultaneously operated over the same COM port using standard Teledyne Instruments’ serial data commands and is compatible with APIcom versions 3.7.3 and later which include an added feature that allows a user to edit, upload and download level tables. 05744 Rev B 79 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12.3. LEVELS A LEVEL is a combination of several parameters: An ID number for the LEVEL An action, (e.g. GENERATE, STANDBY) A target concentration value An output flow rate (if applicable) Configuration for one or both of two status output blocks. Up to twenty levels can be defined and used with the M703E using a range of ID numbers from 0-98. Level 99 is reserved for standby. Are not time based and do not include characteristics such as start time or duration, therefore a single LEVEL can not switch between different concentration levels and flow rates. Separate flow and concentration outputs must be programmed into separate LEVELs which are then individually started and stopped either by an operator at the calibrator’s front panel or through a serial data operation over the RS-232 or Ethernet ports. 6.12.4. ACTIVATING AN EXISTING LEVEL To activate an existing defined LEVEL, press: 80 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12.5. PROGRAMMING NEW LEVELS To begin programming a new LEVEL find the LVL submenu by pressing: STANDBY Make sure that the M703E is in standby mode. <TST TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY SETUP PRIMARY SETUP MENU LEVL SEQ CFG CLK PASS MORE EXIT This display only appears if there are no LEVELs currently programmed into the M703E. OTHERWISE ... SETUP X.X END OF LEVELS INS SETUP X.X [LEVEL ID] ) [Gas/Conc.], [Status Block Set] PREV NEXT INS DEL EDIT PRNT EXIT Scrolls back and forth between existing LEVELS 05744 Rev B EXIT CHOOSE ACTION Submenu SETUP X.X PREV NEXT Deletes the LEVEL shown in the message field PRNT ACTION TO PERFORM:GENERATE ENTR EXIT Edits the LEVEL shown in the message field Use these keys to scroll though the available instructions: GENERATE & MANUAL 81 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12.5.1. Creating a GENERATE LEVEL To create a LEVEL using the M703E’s AUTO generation function, press: Starting at the CHOOSE ACTION Submenu CHOOSE ACTION Submenu SETUP X.X ACTION TO PERFORM:GENERATE PREV NEXT ENTR SETUP X.X GENERATE:ZERO ZERO ENTR SETUP X.X 0 Toggle these keys to set the target concentration. 0 SETUP X.X 0 .0 EXIT EXIT Toggle this key to scroll through the available gas types (as programmed during initial setup. GENERATE:0.0 PPB O3 0 .0 PPB O3 ENTR EXIT Toggle this key to to scroll through the available units of measure GENERATE:0.0 PPB O3 0 0 PCT O3 ENTR EXIT EXIT discards the new setting STANDBY 0 Toggle these keys until the designation of the existing defined level program is reached. 82 LEVEL:0 0 ENTR EXIT EXIT discards the new LEVEL number ENTR accepts the new LEVEL number 05744 Rev B TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12.5.2. Creating a MANUAL LEVEL To create a level using the M703E’s MANUAL generation function, press: Starting at the CHOOSE ACTION Submenu CHOOSE ACTION Submenu SETUP X.X ACTION TO PERFORM:GENERATE NEXT ENTR EXIT Use the NEXT until ... SETUP X.X INSERT STEP: MANUAL PREV ENTR SETUP X.X This Key Turns the the O3 Generator OFF/ON OFF O3 GEN MODE: OFF CNST REF BNCH 0 0 ENTR SETUP X.X O3 GEN SET POINT: 0.0 MV 0 0 .0 ENTR REF: The concentration control loop will use the generator’s reference detector as input. BNCH: The concentration control loop will use the photometer bench. EXIT These keys set a target concentration for the O3 Generator This key sets a CONSTANT drive voltage for the O3 Generator SETUP X.X EXIT 0 EXIT 0 O3 GEN SET POINT: 000.0 PPB 0 0 .0 ENTR EXIT Toggle these keys to set output CONCENTRATION of the O3 generator Toggle these keys to set the CONSTANT drive voltage of the O3 generator STANDBY 0 LEVEL:0 0 Toggle these keys until the designation of the existing defined level program is reached. 05744 Rev B ENTR EXIT EXIT discards the new LEVEL number EXIT discards the new setting ENTR accepts the new setting ENTR accepts the new LEVEL number 83 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12.5.3. Editing or Deleting a LEVEL To edit or delete an existing LEVEL, press: Levels are displayed according to the following Format: LEVEL ID: Any number between 0 and 99. This will be the number used to select the level when activating / deactivating it, or when editing or deleting it. Gas Conc: The concentration setting, in ppb, for the O3 generator to produce. Status Block Setting: This will be displayed as two pairs of 1-digit numbers. The First pair corresponds to Status Block 1. The Second pair corresponds to Status Block 2. n each case: The left digit will be a number between 1 and 4 representing the binary setting of bits 1 through 4 and; The right digit will be a number between 1 and 4 representing the binary setting of bits 5 through 8. 84 05744 Rev B M703E Calibrator Operator’s Manual Figure 6-5: 05744 Rev B TELEDYNE API Operating the M703E Calibrator LEADS Level Display Format 85 TELEDYNE API Operating the M703E Calibrator M703E Calibrator Operator’s Manual 6.12.6. CONFIGURING LEVEL STATUS BLOCKS There are two STATUS BLOCKS associated with LEADS LEVELS. BLOCK 1: This block corresponds to the physical CONTROL OUTPUT connections located on the back panel of the M703E (see Figure 3-2, Figure 3-8 and Section 3.2.5). BLOCK 2: The second status block does not correspond to any physical output but is used to communicate status over the serial data port To configure the either of the STATUS BLOCKS, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU LEVL SEQ CFG CLK PASS MORE EXIT SETUP X.X [LEVEL ID] )[Gas/Conc.],[Status Block Set’g] Toggle these keys until the number of the LEVEL to be edited is reached. PREV NEXT INS SETUP X.X <SET SET> DEL EDIT PRNT See Figure 6-5 EXIT LEVEL NUMBER:12 EDIT EXIT Continue pressing SET> until Desired Status Block is reached SETUP X.X <SET SET> SETUP X.X STATUS BLOCK 2:DISABLED EDIT EXIT STATUS BLOCK 2:OFF OFF ENTER EXIT Toggle this key turn the CC input ON/OFF ENTR accepts the new setting SETUP X.X Moves the cursor one character left or right. EXIT discards the new setting <CH CH> STATUS BLOCK 2:[0]0000000 [0] ENTER EXIT EXIT discards the new setting ENTR accepts the new setting Toggle this key to turn the selected bit ON/OFF (0 or 1). Each bit shown on the display represents one of the control output pins located on the back of the M703E (see Figure 3-2), The left most bit is Bit 1, the next bit to the right, bit 2, progressing rightward to bit 8 (see Figure 3-8 for connector pin assignments) 86 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating The M703E over the Serial I/O Ports 7. OPERATING THE M703E OVER THE SERIAL I/O PORTS 7.1. USING THE ANALYSER’S COMMUNICATION PORTS The M703E is equipped with two serial communication ports located on the rear panel accessible via 2 DB-9 connectors on the back panel of the instrument (See Figure 3-2). The COM1 connector is a male DB-9 connector and the COM2 is a female DB9 connector. Both ports operate similarly and give the user the ability to communicate with, issue commands to, and receive data from the calibrator through an external computer system or terminal. The RS-232 port (COM1) can also be configured to operate in single or RS-232 multidrop mode (option 62; See Section 5.2.3 and7.3. The COM2 port can be configured for standard RS-232 operation, half-duplex RS-485 communication or for access via an LAN by installing the Teledyne Instruments’ Ethernet interface card (see Section 5.2.4 and 7.5). 7.1.1. RS-232 DTE AND DCE COMMUNICATION RS-232 was developed for allowing communications between data terminal equipment (DTE) and data communication equipment (DCE). Basic data terminals always fall into the DTE category whereas modems are always considered DCE devices. Electronically, the difference between the DCE & DTE is the pin assignment of the Data Receive and Data Transmit functions. DTE devices receive data on pin 2 and transmit data on pin 3. DCE devices receive data on pin 3 and transmit data on pin 2. A switch located below the serial ports on the rear panel allows the user to switch between DTE (for use with data terminals) or DCE (for use with modems). Since computers can be either DTE or DCE, check your computer to determine which mode to use. 05744 Rev B 87 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.2. COMM PORT DEFAULT SETTINGS AND CONNECTOR PIN ASSIGNMENTS Received from the factory, the calibrator is set up to emulate an RS-232 DCE device. RS-232 (COM1): RS-232 (fixed), DB-9 male connector. o Baud rate: 19200 bits per second (baud). o Data Bits: 8 data bits with 1 stop bit. o Parity: None. COM2: RS-232 (configurable to RS 485), DB-9 female connector. o Baud rate: 115000 bits per second (baud). o Data Bits: 8 data bits with 1 stop bit. o Parity: None. Female DB-9 (COM2) Male DB-9 (RS-232) (As seen from outside analyzer) (As seen from outside analyzer) TXD TXD GND RXD 1 2 6 3 7 4 8 GND RXD 5 1 9 6 CTS RTS 2 3 7 4 8 5 9 CTS RTS (DTE mode) (DTE mode) RXD GND TXD 1 2 6 3 7 4 8 5 9 RTS CTS (DCE mode) Figure 7-1: Default Pin Assignments for Back Panel COMM Port connectors (RS-232 DCE & DTE) The signals from these two connectors are routed from the motherboard via a wiring harness to two 10-pin connectors on the CPU card, CN3 (COM1) and CN4 (COM2). CN3 & CN4 (Located on CPU card) CTS RTS RXD 2 4 6 8 10 1 3 5 7 9 TXD GND (As seen from inside analyzer) Figure 7-2: 88 Default Pin Assignments for CPU COM Port connector (RS-232). 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual Teledyne Instruments offers two mating cables, one of which should be applicable for your use. Part number WR000077, a DB-9 female to DB-9 female cable, 6 feet long. Allows connection of the serial ports of most personal computers. Also available as Option 60 (See Section 5.2.1). Part number WR000024, a DB-9 female to DB-25 male cable. Allows connection to the most common styles of modems (e.g. Hayes-compatible) and code activated switches. Both cables are configured with straight-through wiring and should require no additional adapters. NOTE Cables that appear to be compatible because of matching connectors may incorporate internal wiring that makes the link inoperable. Check cables acquired from sources other than Teledyne Instruments for pin assignments before using. To assist in properly connecting the serial ports to either a computer or a modem, there are activity indicators just above the RS-232 port. Once a cable is connected between the calibrator and a computer or modem, both the red and green LEDs should be on. If the lights are not lit, use the small switch on the rear panel to switch it between DTE and DCE modes If both LEDs are still not illuminated, make sure the cable properly constructed. 05744 Rev B 89 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.3. COMM PORT BAUD RATE To select the baud rate of either one of the COM Ports, press: STANDBY <TST TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY PRIMARY SETUP MENU SEQ SETUP X.X CFG CLK PASS MORE ID Toggle these keys to cycle through the available Baud rates: 300 1200 4800 9600 19200 38400 57600 115200 COMMUNICATIONS MENU EXIT COM1 MODE:0 SET> EDIT SETUP X.X <SET EXIT COM1 COM2 SETUP X.X <SET EXIT SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X SETUP EXIT COM1 BAUD RATE:19200 SET> EDIT SETUP X.X EXIT COM1 BAUD RATE:19200 PREV NEXT SETUP X.X PREV NEXT ENTR EXIT COM1 BAUD RATE:19200 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 90 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.4. COMM PORT COMMUNICATION MODES Each of the calibrator’s serial ports can be configured to operate in a number of different modes, listed in Table 7-1. As modes are selected, the calibrator sums the Mode ID numbers and displays this combined number on the front panel display. For example, if quiet mode (01), computer mode (02) and Multi-Drop-enabled mode (32) are selected, the Calibrator would display a combined MODE ID of 35. Table 7-1: COMM Port Communication Modes MODE1 ID 1 QUIET DESCRIPTION Quiet mode suppresses any feedback from the calibrator (such as warning messages) to the remote device and is typically used when the port is communicating with a computer program where such intermittent messages might cause communication problems. Such feedback is still available but a command must be issued to receive them. COMPUTER 2 Computer mode inhibits echoing of typed characters and is used when the port is communicating with a computer operated control program. SECURITY 4 When enabled, the serial port requires a password before it will respond. The only command that is active is the help screen (? CR). When turned on this mode switches the COM port settings from 2048 E, 7, 1 No parity; 8 data bits; 1 stop bit to Even parity; 7 data bits; 1 stop bit RS-485 1024 Configures the COM2 Port for RS-485 communication. RS-485 mode has precedence over multidrop mode if both are enabled. MULTIDROP PROTOCOL 32 Multidrop protocol allows a multi-instrument configuration on a single communications channel. Multidrop requires the use of instrument IDs. ENABLE MODEM 64 Enables to send a modem initialization string at power-up. Asserts certain lines in the RS-232 port to enable the modem to communicate. ERROR CHECKING2 128 Fixes certain types of parity errors at certain Hessen protocol installations. XON/XOFF HANDSHAKE2 256 Disables XON/XOFF data flow control also known as software handshaking. HARDWARE HANDSHAKE 8 HARDWARE FIFO2 512 COMMAND PROMPT 4096 Enables CTS/RTS style hardwired transmission handshaking. This style of data transmission handshaking is commonly used with modems or terminal emulation protocols as well as by Teledyne Instrument’s APICOM software. Disables the HARDWARE FIFO (First In – First Out), When FIFO is enabled it improves data transfer rate for that COM port. Enables a command prompt when in terminal mode. 1 Modes are listed in the order in which they appear in the SETUP MORE COMM COM[1 OR 2] MODE menu 2 The default setting for this feature is ON. Do not disable unless instructed to by Teledyne Instruments’ Customer Service personnel. Note Communication Modes for each COM port must be configured independently. 05744 Rev B 91 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual Press the following keys to select communication modes for a one of the COMM Ports, such as the following example where RS-485 mode is enabled: STANDBY <TST TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY SEQ SETUP X.X SETUP PRIMARY SETUP MENU CFG CLK PASS MORE SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X ID <SET PREV EXIT Combined Mode ID displayed here COM1 MODE:0 EXIT COM1 QUIET MODE:OFF NEXT OFF EXIT Continue pressing NEXT until ... SETUP X.X Activate / Deactivate the Selected mode by toggling the ON / OFF key COMMUNICATIONS MENU SET> EDIT SETUP X.X Use the PREV and NEXT Keys to between the available modes EXIT COM1 COM2 SETUP X.X EXIT COM1 RS-485 MODE:OFF PREV NEXT OFF SETUP X.X ENTR EXIT COM1 RS-485 MODE:ON PREV NEXT OFF ENTR EXIT PREV and NEXT Keys to continue selecting other COM modes you want to enable or disable 92 EXIT discards the new setting ENTR accepts the new setting 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating The M703E over the Serial I/O Ports 7.1.5. COMM PORT TESTING The serial ports can be tested for correct connection and output in the COM menu. This test sends a string of 256 ‘w’ characters to the selected COM port. While the test is running, the red LED on the rear panel of the calibrator should flicker. To initiate the test press the following key sequence. 05744 Rev B 93 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.6. MACHINE ID Each type of Teledyne Instruments calibrator is configured with a default ID code. The default ID code for all M703E calibrators is 700. The ID number is only important if more than one calibrator is connected to the same communications channel such as when several calibrators are on the same Ethernet LAN, in a RS-232 multidrop chain (See Section 7.3) or operating over a RS-485 network (See Section 7.4). If two calibrators of the same model type are used on one channel, the ID codes of one or both of the instruments needs to be changed so To edit the instrument’s ID code, press: The ID number is only important if more than one calibrator is connected to the same communications channel (e.g., a multi-drop setup). Different models of Teledyne Instruments’ calibrators have different default ID numbers, but if two calibrators of the same model type are used on one channel (for example, two M703E’s), the ID of one instrument needs to be changed. The ID can also be used for to identify any one of several calibrators attached to the same network but situated in different physical locations. 94 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.7. TERMINAL OPERATING MODES The M703E can be remotely configured, calibrated or queried for stored data through the serial ports. As terminals and computers use different communication schemes, the calibrator supports two communicate modes specifically designed to interface with these two types of devices. Computer mode is used when the calibrator is connected to a computer with a dedicated interface program. Interactive mode is used with a terminal emulation programs such as HyperTerminal or a “dumb” computer terminal. The commands that are used to operate the calibrator in this mode are listed in Table 7-2. 7.1.7.1. Help Commands in Terminal Mode Table 7-2: Terminal Mode Software Commands COMMAND Control-T Switches the calibrator to terminal mode (echo, edit). If mode flags 1 & 2 are OFF, the interface can be used in interactive mode with a terminal emulation program. Control-C Switches the calibrator to computer mode (no echo, no edit). CR (carriage return) BS (backspace) 05744 Rev B Function A carriage return is required after each command line is typed into the terminal/computer. The command will not be sent to the calibrator to be executed until this is done. On personal computers, this is achieved by pressing the ENTER key. Erases one character to the left of the cursor location. ESC (escape) Erases the entire command line. ? [ID] CR This command prints a complete list of available commands along with the definitions of their functionality to the display device of the terminal or computer being used. The ID number of the calibrator is only necessary if multiple calibrators are on the same communications line, such as the multidrop setup. Control-C Pauses the listing of commands. Control-P Restarts the listing of commands. 95 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.7.2. Command Syntax Commands are not case-sensitive and all arguments within one command (i.e. ID numbers, keywords, data values, etc.) must be separated with a space character. All Commands follow the syntax: X [ID] COMMAND <CR> Where X is the command type (one letter) that defines the type of command. Allowed designators are listed in Table 6-27 and Appendix A-6. [ID] is the machine identification number (Section 7.1.6). Example: the Command “? 200” followed by a carriage return would print the list of available commands for the revision of software currently installed in the instrument assigned ID Number 200. COMMAND is the command designator: This string is the name of the command being issued (LIST, ABORT, NAME, EXIT, etc.). Some commands may have additional arguments that define how the command is to be executed. Press ? <CR> or refer to Appendix A-6 for a list of available command designators. <CR> is a carriage return. All commands must be terminated by a carriage return (usually achieved by pressing the ENTER key on a computer). Table 7-3: Teledyne Instruments Serial I/O Command Types COMMAND COMMAND TYPE C Calibration D Diagnostic L Logon T Test measurement V Variable W Warning 7.1.7.3. Data Types Data types consist of integers, hexadecimal integers, floating-point numbers, Boolean expressions and text strings. 96 Integer data are used to indicate integral quantities such as a number of records, a filter length, etc. They consist of an optional plus or minus sign, followed by one or more digits. For example, +1, -12, 123 are all valid integers. Hexadecimal integer data are used for the same purposes as integers. They consist of the two characters “0x,” followed by one or more hexadecimal digits (0-9, A-F, a-f), which is the ‘C’ programming language convention. No plus or minus sign is permitted. For example, 0x1, 0x12, 0x1234abcd are all valid hexadecimal integers. 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating The M703E over the Serial I/O Ports Floating-point numbers are used to specify continuously variable values such as temperature set points, time intervals, warning limits, voltages, etc. They consist of an optional plus or minus sign, followed by zero or more digits, an optional decimal point and zero or more digits. (At least one digit must appear before or after the decimal point.) Scientific notation is not permitted. For example, +1.0, 1234.5678, 0.1, 1 are all valid floating-point numbers. Boolean expressions are used to specify the value of variables or I/O signals that may assume only two values. They are denoted by the keywords ON and OFF. Text strings are used to represent data that cannot be easily represented by other data types, such as data channel names, which may contain letters and numbers. They consist of a quotation mark, followed by one or more printable characters, including spaces, letters, numbers, and symbols, and a final quotation mark. For example, “a”, “1”, “123abc”, and “()[]<>” are all valid text strings. It is not possible to include a quotation mark character within a text string. Some commands allow you to access variables, messages, and other items. When using these commands, you must type the entire name of the item; you cannot abbreviate any names. 7.1.7.4. Status Reporting Reporting of status messages as an audit trail is one of the three principal uses for the RS-232 interface (the other two being the command line interface for controlling the instrument and the download of data in electronic format). You can effectively disable the reporting feature by setting the interface to quiet mode (Section 7.1.4, Table 7-1). Status reports include warning messages, calibration and diagnostic status messages. Refer to Appendix A-3 for a list of the possible messages, and this for information on controlling the instrument through the RS-232 interface. General Message Format All messages from the instrument (including those in response to a command line request) are in the format: X DDD:HH:MM [Id] MESSAGE<CRLF> Where: X is a command type designator, a single character indicating the message type, as shown in the Table 6-27. DDD:HH:MM is the time stamp, the date and time when the message was issued. It consists of the Day-of-year (DDD) as a number from 1 to 366, the hour of the day (HH) as a number from 00 to 23, and the minute (MM) as a number from 00 to 59. [ID] is the calibrator ID, a number with 1 to 4 digits. MESSAGE is the message content that may contain warning messages, Test Functions, variable values, etc. <CRLF> is a carriage return / line feed pair, which terminates the message. The uniform nature of the output messages makes it easy for a host computer to parse them into an easy structure. Keep in mind that the front panel display does not give any information on the time a message was issued, hence it is useful to log such messages for trouble-shooting and reference purposes. Terminal emulation programs such as HyperTerminal can capture these messages to text files for later review. 05744 Rev B 97 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.1.7.5. COM Port Password Security In order to provide security for remote access of the M703E, a LOGON feature can be enabled to require a password before the instrument will accept commands. This is done by turning on the SECURITY MODE (Mode 4, Section 7.1.4). Once the SECURITY MODE is enabled, the following items apply. A password is required before the port will respond or pass on commands. If the port is inactive for one hour, it will automatically logoff, which can also be achieved with the LOGOFF command. Three unsuccessful attempts to log on with an incorrect password will cause subsequent logins to be disabled for 1 hour, even if the correct password is used. If not logged on, the only active command is the '?' request for the help screen. The following messages will be returned at logon: LOGON SUCCESSFUL - Correct password given LOGON FAILED - Password not given or incorrect LOGOFF SUCCESSFUL - Connection terminated successfully To log on to the M703E calibrator with SECURITY MODE feature enabled, type: LOGON 940331 940331 is the default password. To change the default password, use the variable RS232_PASS issued as follows: V RS232_PASS=NNNNNN Where N is any numeral between 0 and 9. 98 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.2. REMOTE ACCESS BY MODEM The M703E can be connected to a modem for remote access. This requires a cable between the calibrator’s COM port and the modem, typically a DB-9F to DB-25M cable (available from Teledyne Instruments with part number WR0000024). Once the cable has been connected, check to make sure: The DTE-DCE is in the DCE position. The M703E COM port is set for a baud rate that is compatible with the modem, The Modem is designed to operate with an 8-bit word length with one stop bit. The MODEM ENABLE communication mode is turned ON (Mode 64, see Section 7.1.4). Once this is completed, the appropriate setup command line for your modem can be entered into the calibrator. The default setting for this feature is AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 This string can be altered to match your modem’s initialization and can be up to 100 characters long. To change this setting press: STANDBY <TST TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY SEQ SETUP PRIMARY SETUP MENU CFG CLK PASS MORE EXIT SETUP X.X <SET SETUP X.X ID SET> EDIT EXIT SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X COM1 MODE:0 Continue pressing <SET or SET> until ... EXIT SETUP X.X COMMUNICATIONS MENU COM1 COM2 EXIT <SET SET> EDIT SETUP X.X The <CH and CH> keys move the cursor left and right along the text string <CH CH> The INS and CH> key inserts a new character before the cursor position 05744 Rev B COM1 PORT INIT:AT Y0 &DO &H &I0 EXIT COM1 PORT INIT:AT Y0 &DO &H &I0 INS DEL [A] ENTR EXIT EXIT discards the new setting ENTR accepts the new setting The DEL deletes character at the cursor position Toggle this key to cycle through the available character set: Alpha: A-Z (Upper and Lower Case); Special Characters: space ’ ~ ! # $ % ^ & * ( ) - _ = +[ ] { } < > | ; : , . / ? Numerals: 0-9 99 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual To Initialize the modem press: STANDBY <TST SEQ SETUP X.X PRIMARY SETUP MENU CFG CLK PASS MORE SETUP X.X <SET EXIT COMMUNICATIONS MENU COM1 COM2 SETUP X.X EXIT SECONDARY SETUP MENU COMM VARS DIAG ID SETUP TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY EXIT COM1 MODE:0 SET> EDIT EXIT Continue pressing <SET or SET> until ... SETUP X.X <SET COM1: INITIALIZE MODEM SET> INIT SETUP X.X INITIALIZING MODE SETUP X.X MODEM INITIALIZED ENTR EXIT Test Runs Automatically PREV NEXT OFF EXIT If there is a problem initializing the modem the message, “MODEM NOT INITIALIZED” will appear. 100 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating The M703E over the Serial I/O Ports 7.3. MULTIDROP RS-232 SET UP The RS-232 multidrop consists of a printed circuit assembly that plugs onto the CN3, CN4 and CN5 connectors of the CPU card and the cabling to connect it to the calibrator’s motherboard. This PCA includes all circuitry required to enable your calibrator for multidrop operation. It converts the instrument’s COM1 port to multidrop configuration allowing up to eight Teledyne Instruments E-Series calibrators or E-Series analyzers to be connected the same I/O port of the host computer. Because both of the DB9 connectors on the calibrator’s back panel are needed to construct the multidrop chain, COM2 is no longer available for separate RS-232 or RS-485 operation; however, with the addition of an Ethernet Option (option 63, See Section5.2.4 and 7.5) the COM2 port is available for communication over a 10BaseT LAN. JP2 Rear Panel CPU Card (as seen from inside) Cable to Ethernet Card Multidrop PCA Cable to Motherboard Figure 7-3: Location of JP2 on RS232-Multidrop PCA (option 62) Each calibrator or analyzer in the multidrop chain must have: One Teledyne Instruments Option 62 installed. One 6’ straight-through, DB9 male DB9 Female cable (Teledyne Instruments P/N WR0000101) is required for each calibrator. To set up the network, for each instrument: 4. Turn the instrument on and change its MACHINE ID code to a unique 4-digit number. 5. Remove the top cover of the instrument and locate JP2 on the multidrop PCA (7-4) 6. Make sure that the jumpers are in place connection pins 9 10 and 11 12. 7. If the instrument is to be the last instrument on the chain, make sure a jumper is in place connecting pins 21 22. 8. If you are adding an instrument to the end of an already existing chain, do not forget to remove JP2, pins 21 22 on the multidrop PCA on the instrument that was previously the last instrument in the chain. 9. Close the instrument. 05744 Rev B 101 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 10. Using straight-through, DB9 male DB9 Female cables, interconnect the host and the calibrators as shown in Figure 6-14. NOTE: Teledyne Instruments recommends setting up the first link, between the Host and the first instrument and testing it before setting up the rest of the chain. KEY: Host Female DB9 RS-232 port Male DB9 CALIBRATOR CALIBRATOR TAPI Analyzer COM2 COM2 COM2 Last INSTRUMENT COM2 RS-232 RS-232 RS-232 RS-232 Make Sure Jumper between JP2 pins 21 22 is installed. Figure 7-4: 102 RS232-Multidrop PCA Host/Calibrator Interconnect Diagram 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.4. RS-485 CONFIGURATION OF COM2 As delivered from the factory, COM2 is configured for RS-232 communications. This port can be re-configured for operation as a non-isolated, half-duplex RS-485 port capable of supporting up to 32 instruments with a maximum distance between the host and the furthest instrument being 4000 feet. If you require full-duplex or isolated operation, please contact Teledyne Instruments Customer Service. To reconfigure COM2 as an RS-285 port set switch 6 of SW1 to the ON position (see Figure 7-6). The RS-485 port can be configured with or without a 150 Ω termination resistor. To include the resistor, install jumper at position JP3 on the CPU board (see Figure 7-6). To configure COM2 as an unterminated RS-485 port leave JP3 open. CN4 JP3 COM2 – RS-232 CN3 COM1 – RS-232 CN5 COM2 – RS-485 SW1 Pin 6 Figure 7-5: 05744 Rev B CPU card Locations of RS-232/485 Switches, Connectors and Jumpers 103 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual When COM2 is configured for RS-485 operation the port uses the same female DB-9 connector on the back of the instrument as when Com2 is configured for RS-232 operation, however, the pin assignments are different. Female DB-9 (COM2) (As seen from outside analyzer) RX/TXGND RX/TX+ 1 2 6 3 7 4 8 5 9 (RS-485) Figure 7-6: Back Panel connector Pin-Outs for COM2 in RS-485 mode. The signal from this connector is routed from the motherboard via a wiring harness to a 6-pin connector on the CPU card, CN5. CN5 (Located on CPU card) RX/TXGND RX/TX+ 2 4 6 1 3 5 (As seen from inside analyzer) Figure 7-7: 104 CPU connector Pin-Outs for COM2 in RS-485 mode. 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.5. REMOTE ACCESS VIA THE ETHERNET When equipped with the optional Ethernet interface, the calibrator can be connected to any standard 10BaseT Ethernet network via low-cost network hubs, switches or routers. The interface operates as a standard TCP/IP device on port 3000. This allows a remote computer to connect through the internet to the calibrator using APICOM, terminal emulators or other programs. The firmware on board the Ethernet card automatically sets the communication modes and baud rate (115,200 kBaud) for the COM2 port. Once the Ethernet option is installed and activated, the COM2 submenu is replaced by a new submenu, INET. This submenu is used to manage and configure the Ethernet interface with your LAN or Internet Server(s). The card has four LEDs that are visible on the rear panel of the calibrator, indicating its current operating status. Table 7-4: Ethernet Status Indicators LED FUNCTION LNK (green) ON when connection to the LAN is valid. ACT (yellow) Flickers on any activity on the LAN. TxD (green) Flickers when the RS-232 port is transmitting data. RxD (yellow) Flickers when the RS-232 port is receiving data. 7.5.1. ETHERNET CARD COM2 COMMUNICATION MODES AND BAUD RATE The firmware on board the Ethernet card automatically sets the communication modes for the COM2 port. The baud rate is also automatically set at 115 200 kBaud. 7.5.2. CONFIGURING THE ETHERNET INTERFACE OPTION USING DHCP The Ethernet option for you M703E uses Dynamic Host Configuration Protocol (DHCP) to configure its interface with your LAN automatically. This requires your network servers also be running DHCP. The calibrator will do this the first time you turn the instrument on after it has been physically connected to your network. Once the instrument is connected and turned on, it will appear as an active device on your network without any extra set up steps or lengthy procedures. NOTE It is a good idea to check the INET settings the first time you power up your calibrator after it has been physically connected to the LAN/Internet to make sure that the DHCP has successfully downloaded the appropriate information from you network server(s). The Ethernet configuration properties are viewable via the calibrator’s front panel. 05744 Rev B 105 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual Table 7-5: LAN/Internet Configuration Properties PROPERTY DEFAULT STATE DESCRIPTION This displays whether the DHCP is turned ON or OFF. DHCP STATUS On Editable INSTRUMENT IP ADDRESS Configured by DHCP EDIT key disabled when DHCP is ON This string of four packets of 1 to 3 numbers each (e.g. 192.168.76.55.) is the address of the calibrator itself. GATEWAY IP ADDRESS Configured by DHCP EDIT key disabled when DHCP is ON A string of numbers very similar to the Instrument IP address (e.g. 192.168.76.1.) that is the address of the computer used by your LAN to access the Internet. SUBNET MASK TCP PORT HOST NAME Configured by DHCP EDIT key disabled when DHCP is ON 3000 Editable, but DO NOT CHANGE M703E Editable Also a string of four packets of 1 to 3 numbers each (e.g. 255.255.252.0) that identifies the LAN to which the device is connected. All addressable devices and computers on a LAN must have the same subnet mask. Any transmissions sent to devices with different subnet masks are assumed to be outside of the LAN and are therefore routed through a gateway computer onto the Internet. This number defines the terminal control port by which the instrument is addressed by terminal emulation software, such as Internet or Teledyne Instruments’ APICOM. The name by which your calibrator will appear when addressed from other computers on the LAN or via the Internet. The default setting for all Teledyne Instruments M703E calibrators is “M703E”. The host name may be changed to fit customer needs. 1 Do not change the setting for this property unless instructed to by Teledyne Instruments Customer Service personnel. NOTE If the gateway IP, instrument IP and the subnet mask are all zeroes (e.g. “0.0.0.0”), the DCHP was not successful in which case you may have to configure the calibrator’s Ethernet properties manually. See your network administrator. 106 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Operating The M703E over the Serial I/O Ports To view the above properties listed in Table 7-5, press: 05744 Rev B 107 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.5.2.1. Manually Configuring the Network IP Addresses There are several circumstances when you may need to configure the interface settings of the calibrator’s Ethernet card manually. The INET sub-menu may also be used to edit the Ethernet card’s configuration properties Your LAN is not running a DHCP software package, The DHCP software is unable to initialize the calibrator’s interface; You wish to program the interface with a specific set of IP addresses that may not be the ones automatically chosen by DHCP. Editing the Ethernet Interface properties is a two-step process. STEP 1: Turn DHCP OFF: While DHCP is turned ON, the ability to set INSTRUMENT IP, GATEWAY IP and SUBNET MASK manually is disabled STANDBY <TST TST> GEN STBY SEQ SETUP X.X O3 ACT =STANDBY SEQ SETUP X.X SETUP PRIMARY SETUP MENU CFG CLK PASS MORE SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X ID ADDR 1 SETUP X.X INET SETUP X.X 8 ENTR EXIT DHCP:ON ENTR accepts the new setting EXIT ignores the new setting EXIT DHCP:ON ON SETUP X.X EXIT ENTER PASSWORD:818 <SET SET> EDIT Toggle this key to turn DHCP ON/OFF EXIT COMMUNICATIONS MENU SETUP X.X 8 EXIT ENTR EXIT DHCP:OFF OFF ENTR EXIT Continue to Step 2 Below 108 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual STEP 2: Configure the INSTRUMENT IP, GATEWAY IP and SUBNET MASK addresses by pressing: Internet Configuration Keypad Functions From Step 1 above) SETUP X.X DHCP: OFF SET> EDIT SETUP X.X EXIT FUNCTION [0] Press this key to cycle through the range of numerals and available characters (“0 – 9” & “ . ”) <CH CH> Moves the cursor one character left or right. DEL Deletes a character at the cursor location. ENTR Accepts the new setting and returns to the previous menu. EXIT Ignores the new setting and returns to the previous menu. Some keys only appear as needed. INST IP: 000.000.000.000 <SET SET> EDIT KEY EXIT SETUP X.X Cursor location is indicated by brackets INST IP: [0] 00.000.000 <CH CH> DEL [0] ENTR EXIT SETUP X.X GATEWAY IP: 000.000.000.000 <SET SET> EDIT EXIT SETUP X.X GATEWAY IP: [0] 00.000.000 <CH CH> DEL [?] ENTR EXIT SETUP X.X SUBNET MASK:255.255.255.0 <SET SET> EDIT EXIT SETUP X.X SUBNET MASK:[2]55.255.255.0 SETUP X.X TCP PORT 3000 <SET Pressing EXIT from any of the above display menus causes the Ethernet option to reinitialize its internal interface firmware <CH CH> EDIT ENTR EXIT The PORT number needs to remain at 3000. Do not change this setting unless instructed to by Teledyne Instruments Customer Service personnel. SETUP X.X SETUP X.X INITIALIZING INET 0% … INITIALIZING INET 100% INITIALIZATI0N SUCCEEDED SETUP X.X ID 05744 Rev B DEL [?] EXIT INET SETUP X.X INITIALIZATION FAILED Contact your IT Network Administrator COMMUNICATIONS MENU COM1 EXIT 109 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.5.3. CHANGING THE CALIBRATOR’S HOSTNAME The HOSTNAME is the name by which the calibrator appears on your network. The default name for all Teledyne Instruments M703E calibrators is M703E. To change this name (particularly if you have more than one M703E calibrator on your network), press. STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SEQ SETUP PRIMARY SETUP MENU CFG CLK PASS MORE EXIT SETUP X.X 8 SETUP X.X ENTER PASSWORD:818 1 8 ENTR EXIT SECONDARY SETUP MENU COMM VARS DIAG EXIT SETUP X.X DHCP:ON <SET SET> EDIT SETUP X.X ID ADDR EXIT COMMUNICATIONS MENU INET EXIT Continue pressing SET> until ... SETUP X.X HOSTNAME: TMS 9000 <SET SET> EDIT KEY Moves the cursor one character to the left. CH> Moves the cursor one character to the right. INS Inserts a character before the cursor location. DEL [?] SETUP X.X FUNCTION <CH <CH CH> EXIT HOSTNAME: TMS 9000 INS DEL [?] ENTR EXIT Deletes a character at the cursor location. Press this key to cycle through the range of numerals and characters available for insertion. 0-9, A-Z, space ’ ~ ! # $ % ^ & * ( ) - _ = +[ ] { } < >\ | ; : , . / ? ENTR Accepts the new setting and returns to the previous menu. EXIT Ignores the new setting and returns to the previous menu. Use these key to edit the HOSTNAME SETUP X.X <CH CH> HOSTNAME: TMS 9K–STACK 2 INS DEL [?] ENTR EXIT Some keys only appear as needed. SETUP X.X ENTR accepts the new setting EXIT ignores the new setting INITIALIZING INET 0% INITIALIZATION process proceeds automatically SETUP X.X INITIALIZATION SUCCEEDED SETUP X.X ID ADDR 110 SETUP X.X INITIALIZATION FAILED COMMUNICATIONS MENU INET EXIT Contact your IT Network Administrator 05744 Rev B TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual 7.6. APICOM REMOTE CONTROL PROGRAM APICOM is an easy-to-use, yet powerful interface program that allows the user to access and control any of Teledyne Instruments’ main line of ambient and stack-gas instruments from a remote connection through direct cable, modem or Ethernet. Running APICOM, a user can: Establish a link from a remote location to the M703E through direct cable connection via RS-232 modem or Ethernet. View the instrument’s front panel and remotely access all functions that could be accessed when standing in front of the instrument. Remotely edit system parameters and set points. Download, view, graph and save data for predictive diagnostics or data analysis. Retrieve, view, edit, save and upload iDAS configurations. Check on system parameters for trouble-shooting and quality control. APICOM is very helpful for initial setup, data analysis, maintenance and trouble-shooting. Figure 7-8 shows examples of APICOM’s main interface, which emulates the look and functionality of the instruments actual front panel Figure 7-8: APICOM Remote Control Program Interface NOTE APICOM is included free of cost with the calibrator and the latest versions can also be downloaded for free at http://www.teledyne-api.com/software/apicom/. The M703E calibrator is fully supported by APICOM revision 3.9.4 and later. Instruments with the LEADS support option must run APICOM revision 4.0 and later 05744 Rev B 111 TELEDYNE API Operating The M703E over the Serial I/O Ports M703E Calibrator Operator’s Manual USER NOTES: 112 05744 Rev B TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8. M703E CALIBRATION AND VERIFICATION Basic electronic calibration of the M703E Calibrator is performed at the factory. Normally there is no need to perform this factory calibration in the field however, the performance of several of the instruments key subsystems should be verified periodically and if necessary adjusted. These subsystems are: O3 Photometer: The O3 photometer performance should be periodically verified against an external standard (see Section 8.1). O3 Generator: The O3 generator should be periodically calibrated (see Section 8.2). 8.1. VERIFYING AND CALIBRATING THE M703E’S O3 PHOTOMETER The accuracy of calibration gas produced by the M703E depends entirely on the accuracy of the photometer; therefore, it is very important that the photometer is operating properly and accurately. The verification procedure can be performed using the instruments internal O3 generator (see Figure 8-1) or an external source of O3 (see Figure 8-2). In either case, an external source of zero air (such as a Teledyne Instruments’ Model 701 Zero Air Generator) is required. 8.1.1. SETUP FOR VERIFYING AND CALIBRATING THE O3 PHOTOMETER Note This operation requires an external reference photometer. 05744 Rev B 113 TELEDYNE API M703E Calibration and Verification Figure 8-1: Figure 8-2: M703E Calibrator Operator’s Manual Set up for Verifying Optional O3 Photometer Using Internal O3 Generator Set up for Verifying Optional O3 Photometer Using an External O3 Generator NOTE The manifolds as shown in the above drawing are oriented to simplify the drawing. All unused ports should be capped. A Minimum of 1.1 LPM is required for the external zero air source 8.1.1.1. Calibration Manifold Exhaust/Vent Line The manifold’s excess gas should be vented to a suitable vent outside of the room. This vent should be of large enough internal diameter to avoid any appreciable pressure drop, and it must be located sufficiently downstream of the output ports to assure that no ambient air enters the manifold due to eddy currents or back diffusion. NOTE It is recommended that the calibration manifold’s exhaust vent have a minimum internal diameter of 3/8 inch and a maximum length of 3 meters (or 10 feet) 114 05744 Rev B TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.1.2. VERIFYING O3 PHOTOMETER PERFORMANCE To verify the performance of the M703E’s optional internal photometer perform the following steps: Make sure that the M703E is in STANDBY mode STANDBY <TST ACT=STANDBY TST> GEN STBY SEQ STANDBY SETUP SYSTEM RESET AUTO STANDBY GENERATE:ZERO ZERO ENTR SETUP STANDBY 0 GENERATE:0.0 PPB O3 0 0 0 PPB O3 ENTR EXIT Toggle these keys to set the target concentration. Toggle this key to set the units of measure. STANDBY 0 GENERATE:0.0 PPB O3 4 GENERATE Wait A MINIMUM OF 10 MINUTES or until the ACT reading settles down Toggle this key to switch to O3 generation mode <SET 0 0 PPB O3 ENTR EXIT ACT = 400 PPB O3 SET> GEN STBY SEQ SETUP Record O3 concentration readings displayed by the ACT test function and by the external reference photometer Repeat this procedure for as many points along the performance range of the M703E as required NOTE The readings recorded from the M703E’s ACT test function and the external reference photometer should be within 1% of each other. 05744 Rev B 115 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.1.3. CALIBRATING THE O3 PHOTOMETER The following procedure sets values held in the calibrator’s memory of for zero point OFFSET and SLOPE. 8.1.3.1. Photometer Zero Calibration To set the zero point offset for the M703E Photometric Calibrator’s photometer, press: 116 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API M703E Calibration and Verification 8.1.3.2. Photometer Span Calibration To set the response SLOPE for the M703E Photometric Calibrator’s photometer, press: 05744 Rev B 117 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.1.4. O3 PHOTOMETER DARK CALIBRATION The Dark Calibration Test turns off the Photometer UV Lamp and records any offset signal level of the UV Detector-Preamp-Voltage to Frequency Converter circuitry. This allows the instrument to compensate for any voltage levels inherent in the Photometer detection circuit that might affect the output of the detector circuitry and therefore the calculation of O3 concentration. STANDBY <TST ACT =STANDBY PRIMARY SETUP MENU SETUP X.X O3 SEQ CFG CLK PASS MORE EXIT O3 GAS CONFIG SETUP X.X MODE SETUP TST> GEN STBY SEQ ADJ PHOT EXIT O3 GAS CONFIG SETUP X.X BCAL DARK EXIT SETUP X.X CALIBRATING DARK OFFSET SETUP X.X DARK CAL 34% COMPLETE The DARK CAL procedure progresses automatically until ... Yes DARK CAL Successful? No SETUP X.X 118 INVALID DARK CAL OFFS=XXXX.X MV 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API M703E Calibration and Verification 8.2. CALIBRATING THE O3 GENERATOR The M703E calibrator’s software includes a routine for automatically calibrating the O3 generator. A calibration table of drive voltages stored in the M703E’s memory is the basis for this calibration. This table is used by the M703E to set initial O3 generator drive settings. 8.2.1. O3 GENERATOR CALIBRATION TABLE When the M703E is operated in BENCH mode, this table is used for the initial setting only. After a short delay time, the bench feedback control will take over and control the O3 generator drive to servo in to the exact concentration requested. When the M703E is operated in CONST mode, the initial O3 generator drive setting will be set by the calibration table and does not change. When the M703E is operated in REF mode, the calibration table sets the initial drive setting and then the reference detector feedback takes over to maintain the lamp at a constant intensity as measured by the reference detector. The target value for the reference detector for a particular target concentration is also stored in this calibration table. The instrument software will interpolate between two values in the table when an intermediate concentration is requested. For each point included in the table used by the M703E to calibrate the optional O3 generator the user can set a drive voltage and a dwell time for that point. Each point can also be individually turned off or on. 05744 Rev B 119 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.2.2. VIEWING O3 GENERATOR CALIBRATION POINTS To view these calibration points, press: STANDBY Make sure that the M703E is in standby mode. <TST ACT =STANDBY PRIMARY SETUP MENU SETUP X.X O3 SETUP TST> GEN STBY SEQ SEQ CFG CLK PASS MORE SECONDARY SETUP MENU SETUP X.X COMM VARS DIAG SETUP X.X 8 EXIT 1 EXIT ENTER PASSWORD 8 ENTR EXIT ENTR EXIT Toggle these keys to enter the correct PASSWORD SIGNAL I/O DIAG PREV NEXT Continue pressing NEXT until ... O3 GEN CALIBRATION DIAG ENTR PREV NEXT O3 GEN CALIBRATION DIAG CAL EXIT PNTS DIAG O3GEN PREV NEXT EXIT 1) 500 MV, 5.0 MIN, ON INS DEL EDIT PRNT EXIT Toggle these keys to move between calibration points 120 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API M703E Calibration and Verification 8.2.3. ADDING OR EDITING O3 GENERATOR CALIBRATION POINTS To add a calibration point to the table or edit an existing point, press: 05744 Rev B 121 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.2.4. DELETING O3 GENERATOR CALIBRATION POINTS To delete an existing calibration point, press: 122 05744 Rev B TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.2.5. TURNING O3 GENERATOR CALIBRATION POINTS ON / OFF To enable or disable an existing calibration point, press: Make sure that the M703E is in standby mode. STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SEQ SETUP X.X SETUP PRIMARY SETUP MENU CFG CLK PASS MORE SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X 8 1 EXIT EXIT ENTER PASSWORD 8 ENTR EXIT ENTR EXIT Toggle these keys to enter the correct PASSWORD DIAG PREV NEXT Continue pressing NEXT until ... DIAG O3 GEN CALIBRATION PREV NEXT DIAG SIGNAL I/O ENTR EXIT O3 GEN CALIBRATION CAL PNTS DIAG O3GEN EXIT 1) 500 MV, 5.0 MIN, ON PREV NEXT INS DEL EDIT PRNT EXIT Continue pressing PREV & NEXT until your reach the point to be turned ON/OFF DIAG O3GEN 8) 1500 MV, 5.0 MIN, ON PREV NEXT DIAG O3GEN <SET INS DEL EDIT PRNT EXIT CAL. POINT DRIVE:0 MV SET> EDIT EXIT Continue pressing SET> until ... DIAG O3GEN <SET DIAG O3GEN Toggle this key to turn the point ON / OFF 05744 Rev B ON CAL. POINT ENABLELD:ON SET> EDIT EXIT CAL. POINT ENABLELD:ON ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 123 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.2.6. PERFORMING AN AUTOMATIC CALIBRATION OF THE O3 GENERATOR To run the automatic O3 generator calibration program, press: 124 05744 Rev B TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.3. M703E GAS PRESSURE SENSOR CALIBRATION The M703E Calibrator has two sensors that monitor the pressure of the gases flowing through the instrument. The data collected by these sensors is used to compensate the final concentration calculations for changes in atmospheric pressure and is stored in the CPU’s memory as test functions: Table 8-1: M703E Pressure Sensors SENSOR Regulator Pressure Sensor Photometer Sample Gas Pressure Sensor ASSOCIATED TEST FUNCTION UNITS REG PRESSURE PSIG PHOTO SPRESS IN-HG-A PRESSURE MONITOR MEASUREMENT POINT Capped fitting on backside of regulator assembly. See Figure 8-4 Use monitor to measure ambient atmospheric pressure at the calibrator’s location. 8.3.1.1. Gas Pressure Sensor Calibration Set Up The procedures described in this section require an independent, calibrated pressure meter/monitor be attached at the following location. M703E Chassis PHOTOMETER BENCH Pressure Monitor DRY AIR IN O3 GAS INPUT PRESSURE SENSOR PHOTOMETER PRESSURE SENSOR Pressure Regulator CHARCOAL SCRUBBER On Back Panel O3 GEN / PHOTOMETER PRESSURE / FLOW SENSOR PCA O3 Generator Assembly O3 GENERATOR ZERO AIR IN Flow Control (100 cm3) Flow Control (5.0 lpm) Flow Control (1.0 LPM) PUMP O3 FLOW SENSOR Filter PHOTOMETER INLET REF/MEAS Valve Flow Control (800 cm3) PHOTOMETER ZERO IN EXHAUST PUMP PHOTOMETER ZERO OUT INTERNAL VENT PHOTOMETER OUTLET TO ANALYZER TO ANALYZER VENT GAS OUTPUT MANIFOLD Figure 8-3: 05744 Rev B Pressure Calibration Monitor Points 125 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual Attach Pressure Monitor Here Outlets to O3 Generator Pressure Regulator Figure 8-4: 126 O3 Generator Pressure Monitor Point Physical Location– M703E 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API M703E Calibration and Verification 8.3.2. CALIBRATING THE REGULATOR AND PHOTOMETER PRESSURE SENSORS 1. Turn off the calibrator and open the top cover. 2. Connect a pressure meter to the Regulator Pressure measurement fitting. This fitting is located on the backside of the regulator assembly (see Figure 8-4). 3. Turn on the calibrator and perform the following steps: 4. Turn OFF the M703E, remove the pressure monitor, replace the cap on the pressure measurement fitting. 05744 Rev B 127 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.4. M703E GAS FLOW CALIBRATION The M703E has two gas flow characteristics that affect its performance: the flow of gas thought the sample chamber of the instrument’s photometer and the total gas flow being output. While both are stored in the calibrator’s memory and used to compensate the final concentration calculations for changes in atmospheric pressure, they are calculated quite differently. PHOTOMETER SAMPLE GAS FLOW RATE: This flow rate is measured directly by a flow sensor located pressure / flow sensor PCA. A slope factor, stored in the calibrator’s memory the last time a PHOTO FLOW calibration operation (see Section 8.4.1) was performed, is and applied to the reading from that sensor. The calculated photometer sample gas flow value is viewable on the instrument’s front panel using the PHOTO FLOW test function and can be output via the M703E’s TEST CHANNEL output using the SAMPLE FLOW function. OUTPUT GAS FLOW RATE: This flow rate is calculated by applying a separate slope factor, also stored in the calibrator’s memory, to an interpolated valued based on the following table of internal gas pressure as measured by the O3 gas input pressure sensor. The output-flow slope value is determined by performing an OUPUT FLOW calibration operation (see Section 8.4.2). Table 8-2: M703E Gas Pressure to Output Flow conversion Table M703E REGULATOR PRESSURE TO OUTPUT FLOW PSIG LPM 0 0.000 1 0.676 2 1.214 3 1.659 4 2.071 5 2.463 6 2.816 7 3.178 8 3.536 9 3.851 10 4.166 15 5.744 20 7.282 25 8.755 30 10.254 35 11.695 40 13.146 The calculated OUTPUT FLOW value is viewable on the instrument’s front panel using the OUTPUT FLOW test function and can be output via the M703E’s TEST CHANNEL using the OUTPUT FLOW function. 128 05744 Rev B TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.4.1. CALIBRATING THE PHOTOMETER’S SAMPLE GAS FLOW NOTE The procedure described in this section requires an independent, calibrated gas flow meter/monitor be connected to the EXHAUST fitting on the back of the M703E. During the PHOTO FLOW calibration, the M703E software automatically turns the DC pump downstream from the photometer ON. To perform a PHOTO FLOW calibration, press: 05744 Rev B 129 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.4.2. CALIBRATING THE OUTPUT GAS FLOW 8.4.2.1. Output Gas Flow Set Up The procedure described in this section requires an independent, calibrated flow meter/monitor and the following set up: O3 FLOW SENSOR O3 Generator Assembly Flow Control (100 cm3/min) Flow Control (5.0 lpm) Flow Control (1.0 LPM) O3 GENERATOR CHARCOAL SCRUBBER CAP CAP CAP Figure 8-5: 130 Output Flow Calibration Monitor Point 05744 Rev B TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual 8.4.2.2. Performing an Output Gas Flow Calibration During the PHOTO FLOW calibration, the M703E software automatically turns the DC pump downstream from the photometer OFF and the AC dry air pump ON. To perform a PHOTO FLOW calibration, press: Make sure that the M703E is in standby mode. STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SETUP PRIMARY SETUP MENU SEQ SETUP X.X CFG CLK PASS MORE SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X 8 EXIT An external flow meter is needed to perform this operation. EXIT ENTER PASSWORD 1 8 ENTR EXIT ENTR EXIT Toggle these keys to enter the correct PASSWORD DIAG SIGNAL I/O PREV NEXT Continue pressing NEXT until ... DIAG FLOW CALIBRATION PREV NEXT ENTR DIAG FCAL DON NOT press the ENTR button at this point. Doing so will cause the slope applied to the Output Flow reading be recalculated. EXIT WAITING FOR FLOW DIAG FCAL ACTUAL PHOTO FLOW: 1.000 LPM 1 .0 0 DIAG FCAL 0 0 ENTR EXIT WAITING FOR FLOW DIAG FCAL ACTUAL OUTPUT FLOW: 1.000 LPM 1 Toggle these keys to match the actual flow as measured by the external flow meter 05744 Rev B .0 0 0 0 ENTR EXIT EXIT discards the new setting ENTR accepts the new setting 131 TELEDYNE API M703E Calibration and Verification M703E Calibrator Operator’s Manual USER NOTES: 132 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API TECHNICAL INFORMATION SECTION III – TECHNICAL INFORMATION 05744 Rev B 133 TELEDYNE API TECHNICAL INFORMATION M703E Calibrator Operator’s Manual USER NOTES: 134 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9. THEORY OF OPERATION 9.1. PNEUMATIC OPERATION 9.1.1. GAS FLOW CONTROL Gas flow rates are set by various flow control assemblies located in the gas stream(s). 9.1.1.1. Flow Control Assemblies O3 FLOW SENSOR O3 Generator Assembly Flow Control (100 cm3/min) Flow Control (5.0 lpm) Flow Control (1.0 to 2.0 LPM) O3 GENERATOR CHARCOAL SCRUBBER Figure 9-1: Location of Gas Flow Control Assemblies 9.1.1.2. Photometer Critical Flow Orifice Critical flow orifices are a remarkably simple way to regulate stable gas flow rates. They operate without moving parts by taking advantage of the laws of fluid dynamics. By restricting the flow of gas though the orifice, a pressure differential is created. This pressure differential combined with the action of the calibrator’s pump draws the gas through the orifice. As the pressure on the downstream side of the orifice (the pump side) continues to drop, the speed that the gas flows though the orifice continues to rise. Once the ratio of upstream pressure to downstream pressure is greater than 2:1, the velocity of the gas through the orifice reaches the speed of sound. As long as that ratio 05744 Rev B 135 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual stays at least 2:1 the gas flow rate is unaffected by any fluctuations, surges, or changes in downstream pressure because such variations only travel at the speed of sound themselves and are therefore cancelled out by the sonic shockwave at the downstream exit of the critical flow orifice. The actual flow rate of gas through the orifice (volume of gas per unit of time), depends on the size and shape of the aperture in the orifice. The larger the hole, the more gas molecules, moving at the speed of sound, pass through the orifice. 9.1.2. INTERNAL GAS PRESSURE SENSORS There are two pressure sensors in the M703E. See Figure 3-3 for the location of the Pressure/Flow PCA. A 100 psig pressure sensor on this PCA is used to monitor the downstream regulator pressure. This value is displayed on the front panel as a test measurement called REG PRESSURE. A second pressure located on the rear PCA measures the pressure of gas in the photometer’s absorption tube. This sensor is a 0-15 psia (absolute pressure) range sensor. This data is used by the CPU when calculating the O3 concentration inside the absorption tube. This value is displayed on the front panel as a test measurement called PHOTO SPRESS. Note that this value is converted to units of Inches of Mercury (IN-HG-A) when displayed on the front panel. 136 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.2. ELECTRONIC OPERATION 9.2.1. OVERVIEW ‘ Analog Outputs TEST CHANNEL OUTPUT Status Outputs 1-8 Aout 4 Aout 3 Control Outputs 1 - 12 Aout 2 Aout 1 COM 2 Control Inputs 1 - 12 Analog Outputs (D/A) Optional Multidrop Card COM 1 Optional Ethernet Card External Digital I/O RS-232 or RS-485 Power Up Circuit O3 Generator Input Pressure Sensor A/D Converter Sensor Inputs Photometer Sample Gas Pressure Sensor Box Temperature RS-232 PC 104 CPU Card PC 104 Bus Disk on Chip Flash Chip CPU Status LED Photometer M/R Valve (Optional) I2C Bus Thermistor Interface O3 Generator O3 Generator UV Reference Lamp Detector RELAY PCA O3 Generator UV Lamp Temperature O3 Generator Lamp Supply Photometer Detector Preamp Photometer Lamp Heater Photometer UV Lamp Temperature I2C Status LED Photometer Sample Gas Temperature Absorption tube Photometer Detector Figure 9-2: O3 Generator Lamp Heater Photometer Pump Keyboard & Display Photometer Lamp Power Supply M703E Electronic Block Diagram At its heart, the calibrator is a microcomputer (CPU) that controls various internal processes, interprets data, makes calculations, and reports results using specialized firmware developed by Teledyne Instruments. It communicates with the user as well as receives data from and issues commands to a variety of peripheral devices via a separate printed circuit assembly called the Mother Board. The motherboard collects data, performs signal conditioning duties and routs incoming and outgoing signals between the CPU and the calibrator’s other major components. Data is generated by the various sub components of the M703E (e.g. flow data from the MFC’s, O3 concentration from the optional photometer). Analog signals are converted into digital data by a unipolar, analog-to-digital converter, located on the motherboard. 05744 Rev B 137 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual A variety of sensors report the physical and operational status of the calibrator’s major components, again through the signal processing capabilities of the motherboard. These status reports are used as data for the concentration calculations and as trigger events for certain control commands issued by the CPU. They are stored in memory by the CPU and in most cases can be viewed but the user via the front panel display. The CPU communicates with the user and the outside world in a variety of manners: Through the calibrator’s keyboard and vacuum florescent display over a clocked, digital, serial I/O bus (using a protocol called I2C); RS 232 & RS485 serial I/O channels; Via an optional Ethernet communications card: Various digital and analog outputs, and A set of digital control input channels. Finally, the CPU issues commands via a series of relays and switches (also over the I2C bus) located on a separate printed circuit assembly to control the function of key electromechanical devices such as heaters, motors and valves. 9.2.2. CPU The CPU is a low power (5 VDC, 0.8A max), high performance, 386-based microcomputer running a version of the DOS operating system. Its operation and assembly conform to the PC-104 specification, version 2.3 for embedded PC and PC/AT applications. It has 2 MB of DRAM memory on board and operates at 40 MHz clock rate over an internal, 32-bit data and address bus. Chip to chip data handling is performed by two 4-channel, direct memory access (DMA) devices over data busses of either 8-bit or 16-bit bandwidth. The CPU supports both RS-232 and RS-485 serial protocols. Figure 9-3 shows the CPU board. The CPU communicates with the user and the outside world in a variety of ways: Through the calibrator’s keyboard and vacuum fluorescence display over a clocked, digital, serial I/O bus using the I2C protocol (read I-square-C bus) RS-232 and/or RS-485 serial ports (one of which can be connected to an Ethernet converter) Various analog voltage and current outputs Several digital I/O channels Figure 9-3: 138 M703E CPU Board Annotated 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Theory of Operation Finally, the CPU issues commands (also over the I2C bus) to a series of relays and switches located on a separate printed circuit assembly, the relay board (located in the right rear of the chassis on its own mounting bracket) to control the function of heaters and valves. The CPU includes two types of non-volatile data storage, one disk-on-chip and one or two flash chips. 9.2.2.1. Disk On Chip Technically, the disk-on-chip is an EEPROM, but appears to the CPU as, behaves as, and performs the same functions in the system as an 8 mb disk drive, internally labeled as DOS drive C:\. It is used to store the computer’s operating system files, the Teledyne Instruments firmware and peripheral files, and the operational data generated by the calibrator’s internal data acquisition system. 9.2.2.2. Flash Chip The flash chip is another, smaller EEPROM with about 64 kb of space, internally labeled as DOS drive B:\. The M703E CPU board can accommodate up to two EEPROM flash chips. The M703E standard configuration is one chip with 64 kb of storage capacity, which is used to store the calibrator configuration as created during final checkout at the factory. Separating these data onto a less frequently accessed chip significantly decreases the chance of data corruption through drive failure. In the unlikely event that the flash chip should fail, the calibrator will continue to operate with just the DOC. However, all configuration information will be lost, requiring the unit to be recalibrated. 05744 Rev B 139 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.2.3. RELAY PCA The relay board is one of the central switching and power distribution units of the calibrator. It contains power relays, valve drivers and status LEDs for all heated zones and valves, as well as thermocouple amplifiers, power distribution connectors and the two switching power supplies of the calibrator. The relay board communicates with the motherboard over the I2C bus. Its status indicators and components can be used for troubleshooting power problems and valve or heater functionality. Generally, the relay PCA is located in the right-rear quadrant of the calibrator and is mounted vertically on the backside of the same bracket as the instrument’s DC power supplies, however the exact location of the relay PCA may differ from model to model (see Figure 3-3.) Status LED’s (D2 through D16) Watchdog Status LED (D1) DC Power Supply Test Points I2C Connector Power Connections for DC Heaters DC Valve & Photometer Pump Control AC Pump Configuration Plug DC Valve Control Drivers AC Power OUT to Dry Air Pump DC Valve & Photometer Pump Control Connector AC Power IN DC Power Distribution Connectors Dry Air AC Pump Control Relay Figure 9-4: Relay Board PCA with AC Relay Retainer Removed This version of the Relay PCA include one AC relays that controls the AC-powered Dry Air (zero air) pump and A plastic insulating safety shield covers the remaining empty AC Relay sockets. CAUTION NEVER REMOVE THIS SAFETY SHIELD WHILE THE INSTRUMENT IS PLUGGED IN AND TURNED ON. THE CONTACTS OF THE AC RELAY SOCKETS BENEATH THE SHIELD CARRY HIGH AC VOLTAGES EVEN WHEN NO RELAYS ARE PRESENT 140 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.2.3.1. Valve Control The relay board also hosts two valve driver IC's, each of which can drive up four valves. In the M703E, the relay PCA controls only those valves associated with the O3 generator and photometer options. 9.2.3.2. Heater Control The relay PCA controls the DC heaters for the O3 generator and photometer lamp housing. Figure 9-5: Heater Control Loop Block Diagram. 9.2.3.3. Relay PCA Status LEDs & Watch Dog Circuitry Thirteen LEDs are located on the calibrator’s relay board to indicate the status of the calibrator’s heating zones and some of its valves as well as a general operating watchdog indicator. Table 11-2 shows the states of these LEDs and their respective functionality. D9 (Green) – Photometer Pump Status D7 (Green) – Photometer Meas/Ref Valve D6 (Green ) – Ext. Zero Air Valve D15 (Yellow) - Photometer Lamp Heater D16 (Yellow) – O3 Generator Lamp Heater D1 (RED) Watchdog Indicator Figure 9-6: 05744 Rev B Status LED Locations – Relay PCA 141 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual Table 9-1: Relay Board Status LEDs LED COLOR DESCRIPTION FUNCTION 2 D1 Red Watchdog Circuit; I C bus operation. Blinks when I2C bus is operating properly D2 Yellow Dry Air Pump Status When lit the zero air AC pump is running. D3-6 D7 SPARE Green Photometer Meas/Ref Valve D8 D9 When lit the valve open to REFERENCE gas path SPARE Green Ext. Zero Air valve Status D10 - 14 When lit the External Zero Air valve is open SPARE D15 Yellow Photometer Heater Status When lit the photometer UV lamp heater is on D16 Yellow O3 Generator Lamp Heater When lit the O3 generator UV lamp heater is on 9.2.3.4. Relay PCA Watchdog Indicator (D1) The most important of the status LEDs on the relay board is the red I2C Bus watchdog LED. It is controlled directly by the calibrator’s CPU over the I2C bus. Special circuitry on the relay PCA watches the status of D1. Should this LED ever stay ON or OFF for 30 seconds (indicating that the CPU or I2C bus has stopped functioning) this Watchdog Circuit automatically shuts all valves and turns off all heaters and lamps. 142 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Theory of Operation 9.2.4. MOTHERBOARD This is the largest electronic assembly in the calibrator and is mounted to the rear panel as the base for the CPU board and all I/O connectors. This printed circuit assembly provides a multitude of functions including A/D conversion, digital input/output, PC-104 to I2C translation, temperature sensor signal processing and is a pass through for the RS-232 and RS-485 signals. 9.2.4.1. A to D Conversion Analog signals, such as the voltages received from the calibrator’s various sensors, are converted into digital signals that the CPU can understand and manipulate by the analog to digital converter (A/D).Under the control of the CPU, this functional block selects a particular signal input and then coverts the selected voltage into a digital word. The A/D consists of a voltage-to-frequency (V-F) converter, a programmable logic device (PLD), three multiplexers, several amplifiers and some other associated devices. The V-F converter produces a frequency proportional to its input voltage. The PLD counts the output of the V-F converter during a specified time period, and sends the result of that count, in the form of a binary number, to the CPU. The A/D can be configured for several different input modes and ranges but in the M703E it is used in uni-polar mode with a +5V full scale. The converter includes a 1% over and under-range. This allows signals from -0.05V to +5.05V to be fully converted. For calibration purposes, two reference voltages are supplied to the A/D converter: Reference ground and +4.096 VDC. During calibration, the device measures these two voltages, outputs their digital equivalent to the CPU. The CPU uses these values to compute the converter’s offset and slope and also uses these factors for subsequent conversions. 9.2.4.2. Sensor Inputs The key analog sensor signals are coupled to the A/D converter through the master multiplexer from two connectors on the motherboard. Terminating resistors (100 kΩ) on each of the inputs prevent cross talk between the sensor signals. 9.2.4.3. Thermistor Interface This circuit provides excitation, termination and signal selection for several negative-coefficient, thermistors (temperature sensors) located inside the calibrator. 9.2.4.4. Analog Outputs The M703E calibrator comes equipped with one analog output. It can be set by the user to carry the current signal level of any one of the parameters (see Table 7-4) and will output an analog VDC signal that rises and falls in relationship with the value of the parameter. 05744 Rev B 143 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.2.4.5. External Digital I/O The external digital I/O performs two functions. The STATUS outputs carry logic-level (5V) signals through an optically isolated 8-pin connector on the rear panel of the calibrator. These outputs convey on/off information about certain calibrator conditions such as CONC VALID. They can be used to interface with certain types of programmable devices. The CONTROL outputs can be used to initiate actions by external peripheral devices in conjunction with individual steps of a calibration sequence (see Section 6.5.1.6). The CONTROL inputs can be initiated by applying 5V DC power from an external source such as a PLC or data logger (Section 6.5.1.5). Zero and span calibrations can be initiated by contact closures on the rear panel. 9.2.4.6. I2C Data Bus I2C is a two-wire, clocked, digital serial I/O bus that is used widely in commercial and consumer electronic systems. A transceiver on the motherboard converts data and control signals from the PC-104 bus to I2C. The data are then fed to the keyboard/display interface and finally onto the relay board. Interface circuits on the keyboard/display interface and relay board convert the I2C data to parallel inputs and outputs. An additional interrupt line from the keyboard to the motherboard allows the CPU to recognize and service key strokes on the keyboard. 9.2.4.7. Power-up Circuit This circuit monitors the +5V power supply during calibrator start-up and sets the analog outputs, external digital I/O ports, and I2C circuitry to specific values until the CPU boots and the instrument software can establish control. 144 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.2.5. POWER SUPPLY AND CIRCUIT BREAKER The M703E calibrator operates in two main AC power ranges: 100-120 VAC and 220-240 VAC (both ± 10%) between 47 and 63 Hz. A 5 ampere circuit breaker is built into the ON/OFF switch. In case of a wiring fault or incorrect supply power, the circuit breaker will automatically turn off the calibrator. NOTE: The M703E calibrator is equipped with a universal power supply that allows it to accept any AC power configuration, within the limits specified in Table 2-2. CAUTION Should the power circuit breaker trip correct the condition causing this situation before turning the calibrator back on. SENSOR SUITES O3 Generator Reference detector, Photometer UV Detector KEY Sensor Control & I/O Logic ANALOG SENSORS Pre-Amplifiers & Amplifiers AC POWER LOGIC DEVICES DC POWER (e.g. CPU, I2C bus, Keyboard, Display, MotherBoard, etc.) AC POWER IN PS 1 GAS TEMPERATURE SENSORS +5 VDC ±15 VDC GAS PRESSURE SENSORS Photometer UV Lamp P/S RELAY PCA ON / OFF SWITCH AC Relay PS 2 (+12 VDC) Solenoid Drivers O3 Generator UV Lamp Xfromer O3 Generator UV Lamp P/S Cooling Fan DRY AIR Pump Photometer M/R valve O3 Generator UV Lamp Figure 9-7: 05744 Rev B Photometer Pump Controlled via I2C M703E Power Distribution Block diagram 145 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.2.6. AC POWER CONFIGURATION The E-Series digital electronic systems will operate with any of the specified power regimes. As long as instrument is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display. Internally, the status LEDs located on the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied. On the other hand, some of the calibrator’s the dry air pump must be properly configured for the type of power being supplied to the instrument. Figure 2-3 shows the location of the Pump AC Configuration jumper. JP7 Pump Configuration Figure 9-8: Location of the AC Configuration Jumper for the Dry Air Pump 9.2.6.1. AC configuration – Internal Pump (JP7) AC power configuration for the internal dry air pump is set using Jumper set JP7. Table 9-2: AC Power Configuration for Internal Pumps (JP7) LINE POWER LINE FREQUENCY JUMPER COLOR 60 HZ WHITE 110VAC 115 VAC 1 50 HZ 220VAC 240 VAC 1 BLACK 60 HZ BROWN 50 HZ1 BLUE FUNCTION JUMPER BETWEEN PINS Connects pump pin 3 to 110 / 115 VAC power line 2 to 7 Connects pump pin 3 to 110 / 115 VAC power line 3 to 8 Connects pump pins 2 & 4 to Neutral 4 to 9 Connects pump pin 3 to 110 / 115 VAC power line 2 to 7 Connects pump pin 3 to 110 / 115 VAC power line 3 to 8 Connects pump pins 2 & 4 to Neutral 4 to 9 Connects pump pins 3 and 4 together 1 to 6 Connects pump pin 1 to 220 / 240VAC power line 3 to 8 Connects pump pins 3 and 4 together 1 to 6 Connects pump pin 1 to 220 / 240VAC power line 3 to 8 A jumper between pins 5 and 10 may be present on the jumper plug assembly, but is only functional on the M300E and has no function on the Models M700E or M703E. 146 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 110 VAC /115 VAC 220 VAC /240 VAC 1 6 1 6 2 7 2 7 3 8 3 8 4 9 4 9 5 10 5 10 Present on 50 Hz version of jumper set, and only functional for M300E Figure 9-9: Pump AC Power Jumpers (JP7) 9.3. FRONT PANEL INTERFACE FASTENER MODE FIELD KEY DEFINITION FIELD LOCKING SCREW KEYBOARD Figure 9-10: MESSAGE FIELD ON / OFF SWITCH FASTENER STATUS LED’s M703E Front Panel Layout The most commonly used method for communicating with the M703E Photometric Calibrator is via the instrument’s front panel, which includes a set of three status LEDs, a vacuum florescent display and a keyboard with 8 context sensitive keys. 05744 Rev B 147 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.3.1.1. Calibrator Status LEDs Three LEDS are used to inform the user of the instruments basic operating status Table 9-3: Front Panel Status LEDs Name Color Main Message Field N/A Mode Field N/A Behavior Displays Warning messages and Test Function values Displays “STANDBY” Significance At initial start up the various warning messages will appear here. Instrument is in STANDBY mode. STATUS LEDs Active Green OFF Auto Yellow OFF Fault Red BLINKING Unit is operating in STANDBY mode. This LED glows green when the instrument is actively producing calibration gas. This LED only glows when the calibrator is performing an automatic calibration sequence. The calibrator is warming up and therefore many of its subsystems are not yet operating within their optimum ranges. Various warning messages will appear. 9.3.1.2. Keyboard A row of eight keys just below the vacuum florescent display (see Figure 9-10) is the main method by which the user interacts with the calibrator. As the software is operated, labels appear on the bottom row of the display directly above each active key, defining the function of that key as it is relevant for the operation being performed. Pressing a key causes the associated instruction to be performed by the calibrator. Note that the keys do not auto-repeat. In circumstances where the same key must be activated for two consecutive operations, it must be released and re-pressed. 9.3.1.3. Display The main display of the calibrator is a vacuum florescent display with two lines of 40 text characters each. Information is organized in the following manner (see Figure 9-10): MODE FIELD: Displays the name of the calibrator’s current operating mode. MESSAGE FIELD: Displays a variety of informational messages such as warning messages, operation data and response messages during interactive tasks. KEY DEFINITION FIELD: Displays the definitions for the row of keys just below the display. These definitions dynamic, context sensitive and software driven. 148 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual Serial Data Display Power Watchdog Clock I2C Interface Display Controller Display Write Keypad Decoder Display Data Decoder Parallel Data Key Press Detect 2 I C to Relay Board I2C to/from CPU Keyboard Interrupt Status Bit 9.3.1.4. Keyboard/Display Interface Electronics From 5 VDC Power Supply Sample LED (Green) Maint. Switch 2nd Lang. Switch Cal LED (Yellow) KEYBOARD 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY Fault LED (Red) Beeper Figure 9-11: Optional Maintenance LED FRONT PANEL Keyboard and Display Interface Block Diagram The keyboard/display interface electronics of the M703E Calibrator watches the status of the eight front panel keys, alerts the CPU when keys are depressed, translates data from parallel to serial and back and manages communications between the keyboard, the CPU and the front panel display. Except for the Keyboard interrupt status bit, all communication between the CPU and the keyboard/display is handled by way of the instrument’s I2C buss. The CPU controls the clock signal and determines when the various devices on the bus are allowed to talk or required to listen. Data packets are labeled with addresses that identify for which device the information is intended. KEYPAD DECODER Each key on the front panel communicates with a decoder IC via a separate analog line. When a key is depressed the decoder chip notices the change of state of the associated signal; latches and holds the state of all eight lines (in effect creating an 8-bit data word); alerts the key-depress-detect circuit (a flip-flop IC); translates the 8-bit word into serial data and; sends this to the I2C interface chip. KEY-PRESS DETECT CIRCUIT This circuit flips the state of one of the inputs to the I2C interface chip causing it to send an interrupt signal to the CPU I2C INTERFACE CHIP This IC performs several functions: Using a dedicated digital status bit, it sends an interrupt signal alerting the CPU that new data from the keyboard is ready to send. Upon acknowledgement by the CPU that it has received the new keyboard data, the I2C interface chip resets the key-depress-detect flip-flop. In response to commands from the CPU, it turns the front panel status LEDs on and off and activates the beeper. Informs the CPU when the optional maintenance and second language switches have been opened or closed (see Chapter 5 for information on these options). 05744 Rev B 149 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual DISPLAY DATA DECODER This decoder translates the serial data sent by the CPU (in TTY format) into a bitmapped image that is sent over a parallel data bus to the display. DISPLAY CONTROLLER This circuit manages the interactions between the display data decoder and the display itself. It generates a clock pulse that keeps the two devices synchronized. It can also, in response to commands from the CPU turn off and/or reset the display. DISPLAY POWER WATCHDOG The M703E calibrator’s display can begin to show garbled information or lock-up if the DC voltage supplied to it falls too low, even momentarily. To alleviate this, a brownout watchdog circuit monitors the level of the power supply and in the event that the voltage level falls below a certain level resets the display by turning it off, then back on. 9.4. SOFTWARE OPERATION The M703E calibrator’s core module is a high performance, 386-based microcomputer running a version of DOS. On top of the DOS shell, special software developed by Teledyne Instruments interprets user commands from various interfaces, performs procedures and tasks, stores data in the CPU’s memory devices and calculates the concentrations in the sample gas. Figure 9-11 shows a block diagram of this software functionality. DOS Shell API FIRMWARE Memory Handling Calibration Data System Status Data Calibrator Operations Calibration Procedures Configuration Procedures Autonomic Systems Diagnostic Routines PC/104 BUS CALIBRATOR HARDWARE Interface Handling Measurement Algorithms for photometer Figure 9-12: 150 Sensor input Data Display Messages Keypad Analog Output Data RS232 & RS485 External Digital I/O PC/104 BUS Schematic of Basic Software Operation 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.5. O3 GENERATOR OPERATION 9.5.1. PRINCIPLE OF PHOTOLYTIC O3 GENERATION Ozone is a naturally occurring substance that is sometimes called "activated oxygen". It contains three atoms of oxygen (O3) instead of the usual two found in normal oxygen (O2) that is essential for life. Because of its relatively short half-life, ozone cannot be bottled and stored for later use and there fore must always be generated on-site by an ozone generator. The two main principles of ozone generation are UV-light and corona discharge. While the corona-discharge method is most common because of its ability to generate very high concentrations (up to 50%), it is inappropriate for calibration needs since the level of fine control over the O3 concentration is poor. Also, the corona discharge method produces a small amount of NO2 as a byproduct, which also may be undesirable in a calibration application The UV-light method is most feasible in calibration application where production of low, accurate concentrations of ozone desired. This method mimics the radiation method that occurs naturally from the sun in the upper atmosphere producing the ozone layer. An ultra-violet lamp inside the generator emits a precise wavelength of UV Light (185 nm). Ambient air] is passed over an ultraviolet lamp, which splits some of the molecular oxygen (O2) in the gas into individual oxygen atoms which attach to other existing oxygen molecules (O2), forming ozone (O3). Figure 9-13: 05744 Rev B O3 Generator Internal Pneumatics 151 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.5.2. GENERATOR PNEUMATIC OPERATION The rate of flow through the O3 generator is controlled by a flow control assembly located on the Regulator SubAssembly in the front of the M703E. O3 Generator Gas Inlet O3 Generator Heater Control PCA O3 Outlet to Photometer and Internal Vent O3 Outlet Measure / Reference Valve for Photometer Bench Figure 9-14: O3 Generator Valve and Gas Fixture Locations 9.5.3. O3 GENERATOR ELECTRONIC OPERATION Electronically the O3 generator and its subcomponents act as peripheral devices operated by the CPU via the motherboard. Sensor signals, such as the UV lamp thermistor are routed to the motherboard, where they are digitized. Digital data is sent by the motherboard to the calibrator’s CPU and where required stored in either flash memory or on the CPU’s disk-on-chip. Commands from the CPU are sent to the motherboard and forwarded to the various devices via the calibrator’s I2C bus. 152 05744 Rev B TELEDYNE API Theory of Operation O3 Generator Sensor Inputs O3 Generator Lamp Heater Thermistor Interface A/D Converter M703E Calibrator Operator’s Manual Figure 9-15: O3 Generator Electronic Block Diagram UV Lamp O3 Generator Heater Control PCA UV Lamp Power Supply (200 VAC @ 30 kHz) UV Lamp Power Supply Transformer Reference Detector Preamp Power Connector Reference Detector Signal Output to Motherboard UV Lamp Power Connector UV Lamp I2C Connector O3 Generator Reference Detector Figure 9-16: 05744 Rev B O3 Generator Reference Detector PCA O3 Generator Electronic Components Location 153 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.5.3.1. O3 Generator Temperature Control In order to operate at peak efficiency the UV lamp of the M703E’s O3 generator is maintained at a constant 48ºC. if the lamp temperature falls below 43ºC or rises above 53ºC a warning is issued by the calibrators CPU. This temperature is controlled as described in the section on the relay PCA (see Section 9.2.3.2). The location of the thermistor and heater associated with the O3 generator is shown below: UV Lamp O3 Generator Heater Control PCA (Heater is located beneath the PCA) UV Lamp Thermistor Figure 9-17: 154 O3 Generator Temperature Thermistor and DC Heater Locations 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.6. PHOTOMETER OPERATION The Model M703E calibrator’s optional photometer determines the concentration of Ozone (O3) in a sample gas drawn through it. Sample and calibration gasses must be supplied at ambient atmospheric pressure in order to establish a stable gas flow through the absorption tube where the gas’ ability to absorb ultraviolet (UV) radiation of a certain wavelength (in this case 254 nm) is measured. Gas bearing O3 and zero air are alternately routed through the photometer’s absorption tube. Measurements of the UV light passing through the sample gas with and without O3 present are made and recorded. Calibration of the photometer is performed in software and does not require physical adjustments. Two internal variables, a slope and offset are used to adjust the calibration of the photometer. The CPU uses these calibration values, the UV absorption measurements made on the sample gas in the absorption tube along with data regarding the current temperature and pressure of the gas to calculate a final O3 concentration. 9.6.1. MEASUREMENT METHOD 9.6.1.1. Calculating O3 Concentration The basic principle by which photometer works is called Beer’s Law (also referred to as the Beer-Lambert equation). It defines the how light of a specific wavelength is absorbed by a particular gas molecule over a certain distance at a given temperature and pressure. The mathematical relationship between these three parameters for gasses at Standard Temperature and Pressure (STP) is: Equation 9-5 I = I0 e -αLC at STP Where: Io is the intensity of the light if there was no absorption. I is the intensity with absorption. L is the absorption path, or the distance the light travels as it is being absorbed. C is the concentration of the absorbing gas. In the case of the Model 703E, Ozone (O ). Α is the absorption coefficient that tells how well O absorbs light at the specific wavelength of interest. 3 3 To solve this equation for C, the concentration of the absorbing Gas (in this case O3), the application of a little algebra is required to rearrange the equation as follows: Equation 9-6 C = ln Io 1 × I αL at STP Unfortunately, both ambient temperature and pressure influence the density of the sample gas and therefore the number of ozone molecules present in the absorption tube thus changing the amount of light absorbed. 05744 Rev B 155 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual In order to account for this effect the following addition is made to the equation: Equation 9-7 C = ln Io I × 1 Τ 29.92 inHg × × αL Ρ 273 o Κ Where: T = sample ambient temperature in degrees Kelvin P = ambient pressure in inches of mercury Finally, to convert the result into Parts per Billion (PPB), the following change is made: Equation 9-8 I C = ln o I 10 9 × αL × Τ 273 o Κ × 29.92 inHg Ρ In a nutshell the M703E photometer: Measures each of the above variables: ambient temperature; ambient gas pressure; the intensity of the UV light beam with and without O3 present; Inserts know values for the length of the absorption path and the absorption coefficient, and: Calculates the concentration of O3 present in the sample gas. 9.6.1.2. The Measurement / Reference Cycle In order to solve the Beer-Lambert equation it is necessary to know the intensity of the light passing through the absorption path both when O3 is present and when it is not. A valve called the measure/reference valve, physically located on front-left corner of the O3 generator assembly (see Figures 3-4 and 9-14) alternates the gas stream flowing to the photometer between zero air (diluent gas) and the O3 output from the O3 generator. This cycle takes about 6 seconds. Table 9-4: M703E Photometer Measurement / Reference Cycle TIME INDEX 0 sec. 0 – 2 sec. 2 – 3 Seconds 3 sec. 3 – 5 sec. 5 – 6 Seconds STATUS Measure/Reference Valve Opens to the Measure Path. Wait Period. Ensures that the Absorption tube has been adequately flushed of any previously present gasses. Analyzer measures the average UV light intensity of O3 bearing Sample Gas (I) during this period. Measure/Reference Valve Opens to the Reference Path. Wait Period. Ensures that the Absorption tube has been adequately flushed of O3 bearing gas. Analyzer measures the average UV light intensity of Non-O3 bearing Sample Gas (I0) during this period. CYCLE REPEAT EVERY 6 SECONDS 156 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual M703E Chassis PHOTOMETER BENCH yel DRY AIR IN blk O3 GAS INPUT PRESSURE SENSOR PHOTOMETER PRESSURE SENSOR Pressure Regulator blu O3 FLOW SENSOR Filter On Back Panel CHARCOAL SCRUBBER pur PHOTOMETER INLET O3 GEN / PHOTOMETER PRESSURE / FLOW SENSOR PCA O3 GENERATOR Flow Control (100 cm3/min) Flow Control (5.0 lpm) Flow Control (1.0 LPM) red O3 Generator Assembly blk orn pur REF/MEAS Valve Flow Control (800 cm3/min) yel grn grn PHOTOMETER ZERO IN EXHAUST PUMP red PHOTOMETER ZERO OUT INTERNAL VENT PUMP orn orn PHOTOMETER OUTLET orn TO ANALYZER ZERO AIR IN blu TO ANALYZER VENT GAS OUTPUT MANIFOLD Figure 9-18: O3 Photometer Gas Flow – Measure Cycle M703E Chassis PHOTOMETER BENCH yel DRY AIR IN blk O3 GAS INPUT PRESSURE SENSOR On Back Panel Filter blu PHOTOMETER PRESSURE SENSOR Pressure Regulator O3 GEN / PHOTOMETER PRESSURE / FLOW SENSOR PCA REF/MEAS Valve PHOTOMETER INLET pur yel Flow Control (800 cm3/min) blk pur grn grn PHOTOMETER ZERO IN orn EXHAUST PUMP red PHOTOMETER ZERO OUT INTERNAL VENT PUMP orn orn orn PHOTOMETER OUTLET TO ANALYZER ZERO AIR IN blu TO ANALYZER VENT GAS OUTPUT MANIFOLD Figure 9-19: 05744 Rev B O3 Photometer Gas Flow – Reference Cycle 157 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.6.1.3. The Absorption Path In the most basic terms, the M703E photometer uses a high energy, mercury vapor lamp to generate a beam of UV light. This beam passes through a window of material specifically chosen to be both non-reactive to O3 and transparent to UV radiation at 254nm and into an absorption tube filled with sample gas. Because ozone is a very efficient absorber of UV radiation the absorption path length required to create a measurable decrease in UV intensity is short enough (approximately 42 cm) that the light beam is only required to make one pass through the Absorption Tube. Therefore, no complex mirror system is needed to lengthen the effective path by bouncing the beam back and forth. Finally, the UV passes through a similar window at the other end of the absorption tube and is detected by a specially designed vacuum diode that only detects radiation at or very near a wavelength of 254nm. The specificity of the detector is high enough that no extra optical filtering of the UV light is needed. The detector reacts to the UV light and outputs a current signal that varies in direct relationship with the intensity of the light shining on it. This current signal is amplified and converted to a 0 to 5 VDC voltage analog signal voltage sent to the instrument’s motherboard where it is digitized. The CPU to be uses this digital data in computing the concentration of O3 in the absorption tube. Window Window UV Detector ABSORPTION TUBE UV Source Sample Gas IN Analog current signal is output by Detector Sample Gas OUT Absorption Path Length = 42 cm Photometer Pre amp PCA Figure 9-20: O-5 VDC analog signal to Motherboard O3 Photometer Absorption Path 9.6.1.4. Interferent Rejection It should be noted that the UV absorption method for detecting ozone is subject to interference from a number of sources. The has M703E’s photometer been successfully tested for its ability to reject interference from sulfur dioxide, nitrogen dioxide, nitric oxide, water, and meta-xylene. While the photometer rejects interference from the aromatic hydrocarbon meta-xylene, it should be noted that there are a very large number of other volatile aromatic hydrocarbons that could potentially interfere with ozone detection. If the M703E calibrator is installed in an environment where high aromatic hydrocarbon concentrations are suspected, specific tests should be conducted to reveal the amount of interference these compounds may be causing. 158 05744 Rev B TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.6.2. PHOTOMETER LAYOUT The Photometer is where the absorption of UV light by ozone is measured and converted into a voltage. It consists of several sub-assemblies: A mercury-vapor UV lamp. This lamp is coated in a material that optically screens the UV radiation output to remove the O3 producing 185nm radiation. Only light at 254nm is emitted. An AC power supply that supplies the current for starting and maintaining the plasma arc of the mercury vapor lamp. A thermistor and DC heater attached to the UV Lamp to maintain the Lamp at an optimum operating temperature. 42 cm long quartz absorption tube. A thermistor attached to the quartz tube for measuring sample gas temperature. Gas inlet and outlet mounting blocks that rout sample gas into and out of the photometer. The vacuum diode, UV detector that converts UV light to a DC current. A preamplifier assembly, which convert the Detector’s current output into a DC Voltage then amplifies it to a level readable by the A to D converter circuitry of the instrument’s motherboard UV Detector Absorption Tube UV Lamp Power Transformer Power Connector from +15 VDC power supply UV Detector Preamp PCA Sample Gas Inlet UV Lamp Power Supply Sample Gas Thermistor UV Lamp Thermistor (UV Lamp Heater Behind Thermistor) Sample Gas Outlet UV Lamp (200 VAC @ 30 kHz) Figure 9-21: UV Lamp Heater Control PCA O3 Photometer Layout – Top Cover Removed 9.6.3. PHOTOMETER PNEUMATIC OPERATION The flow of gas through the photometer is created by a small internal pump that pulls air though the instrument. There are several advantages to this “pull through” configuration. Placing the pump down stream from the absorption tube avoids problems caused by the pumping process heating and compressing the sample. In order to measure accurately the presences of low concentrations of O3 in the sample air it is necessary to establish and maintain a relatively constant and stable volumetric flow of sample gas through the photometer. The simplest way to accomplish this is by placing a flow control assembly containing a critical flow orifice directly upstream of the pump but down stream from the absorption tube. The critical flow orifice installed in the pump supply line is tuned to create a gas flow of 800 cm3/min. A pressure sensor and a flow sensor, located on the O3 generator / photometer pressure flow sensor PCA, monitor the pressure and flow rate of the gas passing through the photometers absorption tube. See Figures 9-18 and 9-19 for depictions of the gas flow related to the photometer. 05744 Rev B 159 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual 9.6.4. PHOTOMETER ELECTRONIC OPERATION MOTHER BOARD A/D Converter PC 104 Bus I C Bus Thermistor Interface Disk on Chip Flash Chip 2 Photometer Sample Gas Pressure Sensor Photometer Detector Preamp PC 104 CPU Card RELAY PCA Photometer UV Lamp Temperature Photometer Sample Gas Temperature Photometer Detector Photometer Lamp Power Supply Absorption tube Photometer M/R Valve (Located on 0# Generator Assembly) I2C y Status LED Photometer Pump Photometer Lamp Heater Photometer Figure 9-22: O3 Photometer Electronic Block Diagram Like the O3 generator, the O3 photometer and its subcomponents act as peripheral devices operated by the CPU via the motherboard. Communications to and from the CPU are handled by the motherboard. Outgoing commands for the various devices such as the photometer pump, the UV lamp power supply the U\V Lamp heater are issued via the I2C bus to circuitry on the relay PCA which turns them ON/OFF. The CPU also issues commands over the I2C bus that cause the relay PCA to cycle the measure/reference valve back and forth. Incoming date the UV light detector is amplified locally then converted to digital information by the motherboard. Output from the photometers temperature sensors is also amplified and converted to digital data by the motherboard. The O3 concentration of the sample gas is computed by the CPU using this data (along with gas pressure and flow data received from the M703E’s pressure sensors. 9.6.4.1. O3 Photometer Temperature Control In order to operate at peak efficiency the UV lamp of the M703E’s O3 photometer is maintained at a constant 58ºC. This is intentionally set at a temperature higher than the ambient temperature of the M703E’s operating environment to make sure that local changes in temperature do not affect the UV Lamp. If the lamp temperature falls below 56ºC or rises above 61ºC a warning is issued by the calibrators CPU. This temperature is controlled as described in the section on the relay PCA (Section 9.3.3.2). The following TEST functions report these temperatures and are viewable from the instrument’s front panel: PHOTO LAMP TEMP - The temperature of the UV Lamp reported in ºC. PHOTO STEMP - The temperature of the Sample gas in the absorption tube reported in ºC. 160 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Theory of Operation 9.6.4.2. Pneumatic Sensors for the O3 Photometer The several sensors located on the pneumatic sensor just to the left rear of the O3 generator assembly measure the absolute pressure and the flow rate of gas inside the photometer’s absorption tube. This information is used by the CPU to calculate the O3 concentration of the sample gas (See Equation 9-7). Both of these measurements are made downstream from the absorption tube but upstream of the pump. A critical flow orifice located between the flow sensor and the pump maintains the gas flow through the photometer at 800 cm3/min. The following TEST functions are viewable from the instrument’s front panel: PHOTO FLOW - The flow rate of gas through the photometer measured in LPM. PHOTO SPRESS – the pressure of the gas inside the absorption tube. This pressure is reported in inches of mercury-absolute (in-Hg-A), i.e. referenced to a vacuum (zero absolute pressure). This is not the same as PSIG. USER NOTES: 05744 Rev B 161 TELEDYNE API Theory of Operation M703E Calibrator Operator’s Manual USER NOTES: 162 05744 Rev B TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operator’s Manual 10. MAINTENANCE SCHEDULE & PROCEDURES Predictive diagnostic functions including failure warnings and alarms built into the calibrator’s firmware allow the user to determine when repairs are necessary without performing painstaking preventative maintenance procedures. For the most part, the M703E calibrator is maintenance free, there are, however, a minimal number of simple procedures that when performed regularly will ensure that the M703E photometer continues to operate accurately and reliably over its the lifetime. Repairs and troubleshooting are covered in Section 11 of this manual. 10.1. MAINTENANCE SCHEDULE Table 10-1 below shows the recommended maintenance schedule for the M703E. Please note that in certain environments (i.e. dusty, very high ambient pollutant levels) some maintenance procedures may need to be performed more often than shown. NOTE A Span and Zero Calibration Check (see CAL CHECK REQ’D Column of Table 10-1) must be performed following certain of the maintenance procedure listed below. See Section 8.1 for instructions on performing a calibration check. CAUTION RISK OF ELECTRICAL SHOCK. DISCONNECT POWER BEFORE PERFORMING ANY OF THE FOLLOWING OPERATIONS THAT REQUIRE ENTRY INTO THE INTERIOR OF THE ANALYZER. NOTE THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY. 05744 Rev B 163 TELEDYNE API Maintenance Schedule & Procedures M703E Photometric O3 Calibrator Operators Manual USER NOTES: 164 05744 Rev B Cal Check Req’d. No Freq Weekly or after any Maintenance or Repair Examine and clean Perform Leak Check Pneumatic lines Yes if cleaned N0 Annually or after any Maintenance or Repair Verify Leak Tight Absorption Tube As needed Yes after cleaning As Needed Inspect --Clean Yes Annually Replace Dry Air Pump Diaphragm 05744 Rev B Manual Section Table 10-1: M703E Maintenance Schedule Date Performed TELEDYNE API Maintenance Schedule & Procedures --- 10.2 10.4 is used with the M703E Calibrator ONLY CLEAN, DRY, PARTICULATE FREE Zero Air (Diluent Gas) 165 Cleaning of the Photometer Absorption Tube Should Not Be Required as long as No Replacement Required. Under Normal Circumstances the Pumps Will Last the Lifetime of the Instrument. Record and analyze Verify Test Functions Photometer Pump Diaphragm Action Item M703E Calibrator Operator’s Manual 166 USER NOTES: TELEDYNE API Maintenance Schedule & Procedures 05744 Rev B M703E Calibrator Operators Manual TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operator’s Manual 10.2. PERFORMING LEAK CHECKS Leaks are the most common cause of analyzer malfunction; Section Error! Reference source not found. presents a simple leak check procedure. Section 10.2.1 describes a more thorough procedure. 10.2.1. PRESSURE LEAK CHECK - BEGINNING OF INSERTION: Replace original section below with this section, per Mike Troy: Obtain a leak checker similar to the Teledyne Instruments’ part number 01960, which contains a small pump, shut-off valve and pressure gauge. Alternatively, a tank of pressurized gas, with the two-stage regulator adjusted to ≤ 15 psi, a shutoff valve and pressure gauge may be used. CAUTION Once the fittings have been wetted with soap solution, do not apply a vacuum as this will cause soap solution to be drawn into the instrument, contaminating it. DO NOT EXCEED 15 PSI PRESSURE. 1. Turn OFF power to the calibrator. 2. Remove the instrument cover 3. Install a leak checker or tank of gas as described above on the “dry air in” port at the rear panel. 4. Install caps on the following fittings on the rear panel. Exhaust Vent Internal Vent Zero Air Inlet Both CALGAS OUT fittings NOTE The M703E calibrator cannot be leak checked with the pump in line due to internal leakage that normally occurs in the pump. 5. Locate the dry air pump. 6. Disconnect the two fittings on the dry air pump and install a union fitting in place of the pump. 7. Locate the photometer pump. 8. Disconnect the two fittings on the photometer pump and install a union fitting in place of the pump. 9. Pressurize the calibrator with the leak checker, allowing enough time to pressurize the instrument fully. 10. Check each fitting with soap bubble solution, looking for bubbles. 05744 Rev B 167 TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operators Manual Once the fittings have been wetted with soap solution. Do not re-apply vacuum as it will draw soap solution into the instrument and contaminate it. Do not exceed 15 psi pressure. 11. Once the leak has been located and repaired, the leak-down rate should be < 1 in-Hg (0.4 psi) in 5 minutes after the pressure is shut off. M703E Chassis PHOTOMETER BENCH yel DRY AIR IN blk O3 GAS INPUT PRESSURE SENSOR PHOTOMETER PRESSURE SENSOR Pressure Regulator blu CHARCOAL SCRUBBER O3 FLOW SENSOR Filter On Back Panel O3 GEN / PHOTOMETER PRESSURE / FLOW SENSOR PCA O3 GENERATOR Flow Control (800 cm3/min) PHOTOMETER INLET pur yel grn UNION grn PHOTOMETER ZERO IN CAP EXHAUST PUMP red CAP UNION Flow Control (100 cm3/min) Flow Control (5.0 lpm) Flow Control (1.0 to 2.0 LPM) red orn REF/MEAS Valve O3 Generator Assembly blk pur PHOTOMETER ZERO OUT INTERNAL VENT orn orn PHOTOMETER OUTLET orn CAP TO ANALYZER PUMP CAP TO ANALYZER VENT CAP CAP ZERO AIR blu IN GAS OUTPUT MANIFOLD Figure 10-1: Pneumatic setup for performing Pressure Leak Checks -END OF INSERTION 168 05744 Rev B TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operator’s Manual If you cannot locate the leak by the above procedure, obtain a leak checker similar to the Teledyne Instruments’ part number 01960, which contains a small pump, shut-off valve and pressure gauge. Alternatively, a tank of pressurized gas, with the two-stage regulator adjusted to ≤ 15 psi, a shutoff valve and pressure gauge may be used. CAUTION Once the fittings have been wetted with soap solution, do not apply / re-apply vacuum as this will cause soap solution to be drawn into the instrument, contaminating it. DO NOT EXCEED 15 PSI PRESSURE. 1. Turn OFF power to the instrument. 2. Install a leak checker or tank of gas as described above on the sample inlet at the rear panel. 3. Install caps on the following fittings on the rear panel. Exhaust Vent Internal Vent Zero Air Inlet Both CALGAS OUT fittings 05744 Rev B 169 TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operators Manual NOTE The M703E calibrator cannot be leak checked with the pump in line due to internal leakage that normally occurs in the pump. 1. Remove the instrument cover 2. Locate the photometer pump. 3. Disconnect the two fittings on the photometer pump and install a union fitting in place of the pump. 4. Locate the dry air pump. 5. Disconnect the two fittings on the dry air pump and install a union fitting in place of the pump. 6. Locate the photometer pump. 7. Disconnect the two fittings on the photometer pump and install a union fitting in place of the pump. 8. Pressurize the instrument with the leak checker, allowing enough time to pressurize the instrument fully. 9. Check each fitting with soap bubble solution, looking for bubbles. Once the fittings have been wetted with soap solution. Do not re-apply vacuum as it will draw soap solution into the instrument and contaminate it. Do not exceed 15 psi pressure. 10. Once the leak has been located and repaired, the leak-down rate should be < 1 in-Hg (0.4 psi) in 5 minutes after the pressure is shut off. M703E Chassis PHOTOMETER BENCH yel DRY AIR IN blk O3 GAS INPUT PRESSURE SENSOR PHOTOMETER PRESSURE SENSOR Pressure Regulator CHARCOAL SCRUBBER O3 FLOW SENSOR Filter blu On Back Panel O3 GEN / PHOTOMETER PRESSURE / FLOW SENSOR PCA O3 GENERATOR Flow Control (800 cm3/min) yel grn grn PHOTOMETER ZERO IN CAP EXHAUST PUMP red PHOTOMETER ZERO OUT CAP INTERNAL VENT orn orn PHOTOMETER INLET pur UNION UNION Flow Control (100 cm3/min) Flow Control (5.0 lpm) Flow Control (1.0 to 2.0 LPM) red orn REF/MEAS Valve O3 Generator Assembly blk pur PHOTOMETER OUTLET orn CAP TO ANALYZER PUMP CAP TO ANALYZER VENT CAP CAP ZERO AIR blu IN GAS OUTPUT MANIFOLD Figure 10-2: 170 Pneumatic setup for performing Pressure Leak Checks 05744 Rev B TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operator’s Manual 10.3. CLEANING OR REPLACING THE ABSORPTION TUBE NOTE: Although this procedure should never be needed as long as the user is careful only to supply the photometer with clean, dry and particulate free zero air, it is included here for those rare occasions when cleaning or replacing the absorption tube may be required. 1. Remove the center cover from the optical bench. 2. Unclip the sample thermistor from the tube. 3. Loosen the two screws on the round tube retainers at either end of the tube. 4. Using both hands, carefully rotate the tube to free it. 5. Slide the tube towards the lamp housing. The front of the tube can now be slid past the detector block and out of the instrument. CAUTION DO NOT CAUSE THE TUBE TO BIND AGAINST THE METAL HOUSINGS. THE TUBE MAY BREAK AND CAUSE SERIOUS INJURY. 6. Clean the tube with Distilled or de-ionized water by running a swab from end-to-end. 7. Air-dry the tube. 8. Check the cleaning job by looking down the bore of the tube. It should be free from dirt and lint. 9. Inspect the o-rings that seal the ends of the optical tube (these o-rings may stay seated in the manifolds when the tube is removed.) If there is any noticeable damage to these o-rings, they should be replaced. 10. Re-assemble the tube into the lamp housing and perform an AUTO LEAK CHECK on the instrument. NOTE: It is important for proper optical alignment that the tube be pushed all the way towards the front of the optical bench when it is re-assembled. This will ensure that the tube is assembled with the forward end against the stop inside the detector manifold. 10.4. REBUILDING THE DRY AIR PUMP The diaphragm in the sample pump will periodically wear out and require replacement. A sample rebuild kit is available. See Appendix B of this manual for the part number of the pump rebuild kit. Instructions and diagrams are included with the kit. Always perform a Flow and Leak Check after rebuilding the Sample Pump. 05744 Rev B 171 TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operators Manual 10.5. PHOTOMETER UV SOURCE LAMP ADJUSTMENT This procedure details the steps for adjustment of the UV source lamp in the optical bench assembly. This procedure should be done whenever the PHOTO REFERENCE test function value drops below 3000 mV. 1. Make sure the analyzer is warmed-up and has been running for at least 15 minutes before proceeding. 2. Remove the cover from the analyzer. 3. Locate the optional Photometer (see Figure 3-3) 4. Locate the UV DETECTOR GAIN ADJUST POT on the photometer assembly (see Figure 10-3). 5. Perform the following procedure: Make sure that the M703E is in standby mode. STANDBY <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SEQ SETUP X.X PRIMARY SETUP MENU CFG CLK PASS MORE 8 1 EXIT SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X SETUP EXIT ENTER PASSWORD 8 ENTR EXIT ENTR EXIT PRNT EXIT ENTR EXIT Toggle these keys to enter the correct PASSWORD DIAG SIGNAL I/O PREV NEXT DIAG I/O 1) CONTROL_IN_2=OFF PREV NEXT JUMP DIAG I/O 1 Toggle these keys to show the ID number for the desired signal (see Appendix A) JUMP TO:1 7 DIAG 17) PHOTO_DET = 3342.2 MV PREV NEXT PRNT EXIT Using an insulated pot adjustment tool, Turn the UV DETECTOR GAIN ADJUSTMENT POT until the value of PHOTO_DET is as close as possible to 4600.0 MV. If a minimum reading of 3500.0 mV can not be reached, the lamp must be replaced. Additional adjustment can be made by physically rotating the lamp in it’s housing. To do this, slightly loosen the UV lamp setscrew. Next, slowly rotate the lamp up to ¼ turn in either direction while watching the PHOTO_DET signal. Once the optimum lamp position is determined, re-tighten the lamp setscrew 6. Replace the cover on the analyzer. 172 05744 Rev B TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operator’s Manual Figure 10-3: Photometer – Location of UV Detector Gain Adjustment & UV Lamp Set Screw 10.6. PHOTOMETER UV SOURCE LAMP REPLACEMENT This procedure details the steps for replacement of the UV source lamp in the optical bench assembly. This procedure should be done whenever the lamp can no longer be adjusted as described in Section 10.2.3. 1. Turn the analyzer off. 2. Remove the cover from the analyzer. 3. Locate the Optical Bench Assembly (see Figure 3-3) 4. Locate the UV lamp at the rear of the optical bench assembly (see Figure 10-3) 5. Unplug the lamp cable from the power supply connector on the side of the optical bench. 6. Slightly loosen (do not remove) the UV lamp setscrew and pull the lamp from its housing. 7. Install the new lamp in the housing, pushing it all the way in. Leave the UV lamp setscrew loose for now. 8. Turn the analyzer back on and allow it to warm up for at least 15 minutes. 9. Turn the UV detector gain adjustment pot (See Figure 10-3) clockwise to its minimum value. The pot should click softly when the limit is reached. 10. Perform the UV Lamp Adjustment procedure described in Section 10.5, with the following exceptions: Slowly rotate the lamp in its housing (up to ¼ turn in either direction) until a MAXIMUM value (or 4600 mVDC) is observed. Make sure the lamp is pushed all the way into the housing while performing this rotation. If the PHOTO_DET will not drop below 5000 mV while performing this rotation, contact T-API Customer Service for assistance. Once a lamp position is found that corresponds to a maximum observed value for PHOTO_DET, tighten the lamp setscrew at the approximate maximum value observed. If the value of PHOTO_DET is not within the range of 4400 – 4600 mV, adjust it accordingly. 11. Replace the cover on the analyzer. NOTE The UV lamp contains mercury (Hg), which is considered hazardous waste. The lamp should be disposed of in accordance with local regulations regarding waste containing mercury. 05744 Rev B 173 TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operators Manual 10.7. ADJUSTMENT OR REPLACEMENT OF OZONE GENERATOR UV LAMP This procedure details the steps for replacement and initial adjustment of the ozone generator lamp. If you are adjusting an existing lamp, skip to Step 8. 1. Turn off the analyzer. 2. Remove the cover from the analyzer. 3. Locate the O3 generator (see Figure 3-3). UV Lamp Set Screws Lamp O-ring O3 Generator Body Figure 10-4: O3 Generator Temperature Thermistor and DC Heater Locations 4. Remove the two setscrews on the top of the O3 generator and gently pull out the old lamp. 5. Inspect the o-ring beneath the nut and replace if damaged. 6. Install the new lamp in O3 generator housing. Do not fully tighten the setscrews. The lamp should be able to be rotated in the assembly by grasping the lamp cable. 7. Turn on analyzer and allow it to stabilize for at least 20 minutes. 8. Locate the O3 generator reference detector adjustment potentiometer. O3 Generator Body Adjustment Pot O3 Generator Reference Detector PCA Figure 10-5: 174 Location of O3 Generator Reference Detector Adjustment Pot 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API Maintenance Schedule & Procedures 9. Perform the following procedure: 10. Tighten the two set -screws. 11. Replace the calibrator’s cover 12. Perform an auto-leak check (See Section 10.2.1). 13. Calibrate the Ozone Generator calibration (see Section 8.2 Calibrating the O3 Generator ??) 05744 Rev B 175 TELEDYNE API Maintenance Schedule & Procedures M703E Calibrator Operators Manual USER NOTES: 176 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11. GENERAL TROUBLESHOOTING & REPAIR OF THE M703E CALIBRATOR This section contains a variety of methods for identifying and solving performance problems with the calibrator. NOTE The operations outlined in this chapter must be performed by qualified maintenance personnel only. CAUTION Risk of electrical shock. Some operations need to be carried out with the instrument open and running. Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to the calibrator. Do not drop tools into the calibrator or leave those after your procedures. Do not shorten or touch electric connections with metallic tools while operating inside the calibrator. Use common sense when operating inside a running calibrator. 11.1. GENERAL TROUBLESHOOTING The M703E Photometric Calibrator has been designed so that problems can be rapidly detected, evaluated and repaired. During operation, it continuously performs diagnostic tests and provides the ability to evaluate its key operating parameters without disturbing monitoring operations. A systematic approach to troubleshooting will generally consist of the following five steps: 14. Note any warning messages and take corrective action as necessary. 15. Examine the values of all TEST functions and compare them to factory values. Note any major deviations from the factory values and take corrective action. 16. Use the internal electronic status LEDs to determine whether the electronic communication channels are operating properly. Verify that the DC power supplies are operating properly by checking the voltage test points on the relay PCA. Note that the calibrator’s DC power wiring is color-coded and these colors match the color of the corresponding test points on the relay PCA. 17. Suspect a leak first! Customer service data indicate that the majority of all problems are eventually traced to leaks in the internal pneumatics of the calibrator or the diluent gas and source gases delivery systems. Check for gas flow problems such as clogged or blocked internal/external gas lines, damaged seals, punctured gas lines, a damaged / malfunctioning pumps, etc. 05744 Rev B 177 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 18. Follow the procedures defined in Section 3.4.4 to confirm that the calibrator’s vital functions are working (power supplies, CPU, relay PCA, keyboard, PMT cooler, etc.). See Figure 3-3 for general layout of components and sub-assemblies in the calibrator. See the wiring interconnect diagram and interconnect list in Appendix D. 11.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES The most common and/or serious instrument failures will result in a warning message being displayed on the front panel. Table 11-1 lists warning messages, along with their meaning and recommended corrective action. It should be noted that more than two or three warning messages occurring at the same time is often an indication that some fundamental sub-system (power supply, relay PCA, motherboard) has failed rather than an indication of the specific failures referenced by the warnings. In this case, it is recommended that proper operation of power supplies (See Section 11.4.3), the relay PCA (See Section 11.4.6), and the motherboard (See Section11.4.8) be confirmed before addressing the specific warning messages. The M703E will alert the user that a Warning Message is active by displaying the keypad label MSG on the Front Panel. In this case, the Front panel display will look something like the following: STANDBY TEST LAMP DRIVER WARNING GEN STBY MSG CLR SETUP The calibrator will also alert the user via the Serial I/O COM port(s) and cause the FAULT LED on the front panel to blink. To view or clear the various warning messages press: STANDBY Suppresses the warning messages TEST GEN STBY SEQ MSG CLR SETUP STANDBY TEST TEST ANALOG CAL WARNING TEST Press CLR to clear the current message. If more than one warning is active, the next message will take its place. CLR SETUP STANDBY <TST MSG returns the active warnings to the message field. SYSTEM RESET GEN STBY SEQ MSG CLR SETUP SYSTEM 178 SYSTEM RESET GEN STBY SEQ MSG CLR SETUP STANDBY Once the last warning has been cleared, the MESSAGE FIELD will return to displaying the currently selected TEST FUNCTION and value. SYSTEM RESET ACT =STANDBY TST> GEN STBY SEQ SETUP NOTE: If a warning message persists after several attempts to clear it, the message may indicate a real problem and not an artifact of the warm-up period 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator Table 11-1: Front Panel Warning Messages WARNING FAULT CONDITION CONFIG INITIALIZED Configuration and Calibration data reset to original Factory state. DATA INITIALIZED Data Storage in iDAS was erased. FRONT PANEL WARN The CPU is unable to Communicate with the Front Panel Display Keyboard LAMP DRIVER WARN The CPU is unable to communicate with either the O3 generator or 2 photometer lamp I C driver chip. O3 GEN LAMP TEMP WARNING IZS Ozone Generator Temp is outside of control range of 48C 3C. O3 GEN REFERENCE WARNING1 The O3 generator’s reference detector output has dropped below 50 mV.1 O3 PUMP WARNING 1 The photometer pump failed to turn on within the specified timeout period (default = 30 sec.). PHOTO LAMP TEMP WARNING The photometer lamp temp is < 51C or >61C. PHOTO LAMP STABILITY WARNING Value output during the Photometer’s reference cycle changes from measurements to measurement more than 25% of the time. PHOTO REFERENCE WARNING Occurs when Ref is <2500 mVDC or >4950 mVDC. REAR BOARD NOT DET Mother Board not detected on power up. POSSIBLE CAUSES - Failed Disk on Chip - User has erased configuration data - Failed Disk-on-Chip. User cleared data. WARNING only appears on Serial I/O COM Port(s) Front Panel Display will be frozen, blank or will not respond. Failed Keyboard 2 I C Bus failure Loose Connector/Wiring 2 I C has failed - No IZS option installed, instrument improperly configured - O3 generator heater - O3 generator temperature sensor - Relay controlling the O3 generator heater - Entire Relay PCA - I2C Bus Possible failure of: - O3 generator UV Lamp - O3 generator reference detector - O3 generator lamp power supply 2 - I C bus - Failed Pump - Problem with Relay PCA - 12 VDC power supply problem Possible failure of: - Bench lamp heater - Bench lamp temperature sensor - Relay controlling the bench heater - Entire Relay PCA - I2C Bus - Hot” Lamp - Faulty UV source lamp - Noisy UV detector - Faulty UV lamp power supply - Faulty ± 15 VDC power supply Possible failure of: - UV Lamp - UV Photo-Detector Preamp - THIS WARNING only appears on Serial I/O COM Port(s) Front Panel Display will be frozen, blank or will not respond. - Failure of Mother Board (table continued) 05744 Rev B 179 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator Table 11-1: WARNING RELAY BOARD WARN M703E Calibrator Operators Manual Front Panel Warning Messages (cont.) FAULT CONDITION The CPU cannot communicate with the Relay PCA. The computer has rebooted. SYSTEM RESET POSSIBLE CAUSES - 2 I C Bus failure Failed relay PCA Loose connectors/wiring This message occurs at power on. If it is confirmed that power has not been interrupted: Failed +5 VDC power Fatal error caused software to restart Loose connector/wiring 11.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS Besides being useful as predictive diagnostic tools, the test functions viewable from the calibrators front panel can be used to isolate and identify many operational problems when combined with a thorough understanding of the calibrators Theory of Operation (see Chapter 9). The acceptable ranges for these test functions are listed in the “Nominal Range” column of the calibrator Final Test and Validation Data Sheet shipped with the instrument. Values outside these acceptable ranges indicate a failure of one or more of the calibrator’s subsystems. Functions whose values are still within the acceptable range but have significantly changed from the measurement recorded on the factory data sheet may also indicate a failure. A worksheet has been provided in Appendix C to assist in recording the value of these Test Functions. Table 11-2 contains some of the more common causes for these values to be out of range. Table 11-2: Test Functions - Indicated Failures TEST FUNCTION 1 O3 GEN REF DIAGNOSTIC RELEVANCE AND CAUSES OF FAULT CONDITIONS. Possible causes of faults are the same as O3 GEN REFERENCE WARNING from Table 11-1 Gas flow problems directly affect the concentration accuracy of the M703E’s O3 calibration gases. This number is computed using data from the calibrator’s OUTPUT FLOW - Check for Gas Flow problems. - Check the pressure regulator O3 GEN DRIVE O3 LAMP TEMP REG PRESSURE BOX TEMP Check the O3 generator heater and temperature sensors Possible causes of faults are the same as O3 GEN LAMP TEMP WARNING from Table 11-1 Incorrect Lamp temperature can affect the efficiency and durability of the O3 generators UV lamp. Possible causes of faults are the same as O3 GEN LAMP TEMP WARNING from Table 11-1 Same as REGULATOR PRESSURE WARNING from Table 11-1 If the Box Temperature is out of range, make sure that the: Box Temperature typically runs ~7C warmer than ambient temperature. - The Exhaust-Fan is running - The there is sufficient open space to the side and rear of instrument to allow adequate ventilation. (table continued) 180 05744 Rev B M703E Calibrator Operator’s Manual Table 11-2: TEST FUNCTION TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator Test Functions - Indicated Failures DIAGNOSTIC RELEVANCE AND CAUSES OF FAULT CONDITIONS. If the value displayed is too high the UV Source has become brighter. Adjust the variable gain potentiometer on the UV Preamp Board in the optical bench. If the value displayed is too low: - < 100mV – Bad UV lamp or UV lamp power supply. - < 2000mV – Lamp output has dropped, adjust UV Preamp Board or replace lamp. PHOTO MEASURE & PHOTO REFERENCE If the value displayed is constantly changing: - Bad UV lamp. - Defective UV lamp power supply. 2 - Failed I C Bus. If the PHOTO REFERENCE value changes by more than 10mV between zero and span gas: - Defective/leaking switching valve. PHOTO FLOW Gas flow problems directly affect the accuracy of the photometer measurements and therefore the concentration accuracy of cal gas mixtures involving O3 and GPT mixtures. - Check for Gas Flow problems. PHOTO LAMP TEMP Poor photometer temp control can cause instrument noise, stability and drift. Temperatures outside of the specified range or oscillating temperatures are cause for concern. Possible causes of faults are the same as PHOTO LAMP TEMP WARNING from Table 11-1 PHOTO SPRESS The pressure of the gas in the photometer’s sample chamber is used to calculate the concentration of O3 in the gas stream. Incorrect sample pressure can cause inaccurate readings. - Check for Gas Flow problems. See Section Table 11-1. The temperature of the gas in the photometer’s sample chamber is used to calculate the concentration of O3 in the gas stream. Incorrect sample temperature can cause inaccurate readings. Possible causes of faults are: PHOTO STEMP PHOTO SLOPE PHOTO OFFSET TIME 05744 Rev B - Bad bench lamp heater - Failed sample temperature sensor - Failed relay controlling the bench heater - Failed Relay PCA 2 - I C Bus malfunction - Hot Lamp Values outside range indicate: Contamination of the Zero Air or Span Gas supply. Instrument is miss-calibrated. Blocked Gas Flow. Faulty Sample Pressure Sensor or circuitry. Bad/incorrect Span Gas concentration. Values outside range indicate: Contamination of the Zero Air supply. Time of Day clock is too fast or slow. To adjust see Section 6.7.2. Battery in clock chip on CPU board may be dead. 181 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.1.3. USING THE DIAGNOSTIC SIGNAL I/O FUNCTION The Signal I/O parameters found under the DIAG Menu combined with a thorough understanding of the instruments Theory of Operation (found in Chapter 9) are useful for troubleshooting in three ways: The technician can view the raw, unprocessed signal level of the calibrator’s critical inputs and outputs. Many of the components and functions that are normally under algorithmic control of the CPU can be manually exercised. The technician can directly control the signal level Analog and Digital Output signals. This allows the technician to observe systematically the effect of directly controlling these signals on the operation of the calibrator. Figure 11-1 is an example of how to use the Signal I/O menu to view the raw voltage of an input signal or to control the state of an output voltage or control signal. The specific parameter will vary depending on the situation. Figure 11-1: 182 Example of Signal I/O Function 05744 Rev B TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operator’s Manual 11.2. USING THE ANALOG OUTPUT TEST CHANNEL The signals available for output over the M703E’s analog output channel can also be used as diagnostic tools. See Section 6.9 for instruction on activating the analog output and selecting a function. Table 11-3: Test Channel Outputs as Diagnostic Tools TEST CHANNEL DESCRIPTION CAUSES OF EXTREMELY HIGH / LOW READINGS TEST CHANNEL IS TURNED OFF NONE O3 PHOTO MEAS FULL SCALE ZERO The raw output of the photometer during its measure cycle 0 mV 5000 mV* If the value displayed is: - >5000 mV: The UV source has become brighter. Adjust the UV Detector Gain potentiometer. - < 100mV – Bad UV lamp or UV lamp power supply. - < 2000mV – Lamp output has dropped, adjust UV Preamp Board or replace lamp. If the value displayed is constantly changing: - Bad UV lamp. - Defective UV lamp power supply. 2 - Failed I C Bus. O3 PHOTO REF The raw output of the photometer during its reference cycle 0 mV 5000 mV O3 GEN REF The raw output of the O3 generator’s reference detector 0 mV 5000 mV OUTPUT FLOW Output flow rate (computed from regulator pressure). 0 LPM 6.000 LPM Possible causes of faults are the same as O3 GEN REFERENCE WARNING from Table 11-1 SAMPLE PRESSURE The pressure of gas in the photometer absorption tube 0 "Hg 40 "Hg-In-A Check for Gas Flow problems. SAMPLE FLOW The gas flow rate through the photometer 0 cm /min 3 1000 cc/m Check for Gas Flow problems. SAMPLE TEMP The temperature of gas in the photometer absorption tube 0 C 70 C PHOTO LAMP TEMP The temperature of the photometer UV lamp 0 C 70 C O3 LAMP TEMP The temperature of the O3 generator’s UV lamp 0 mV 5000 mV CHASSIS TEMP The temperature inside the M703E’s chassis (same as BOX TEMP) 0 C 70 C O3 PHOTO CONC The current concentration of O3 being measured by the photometer. 05744 Rev B --- If the PHOTO REFERENCE value changes by more than 10mV between zero and span gas: - Defective/leaking M/R switching valve. Possible causes of faults are the same as OUTPUT FLOW from Table 11-2. Possible causes of faults are the same as PHOTO STEMP from Table 11-2 Possible failure of: - Bench lamp heater - Bench lamp temperature sensor - Relay controlling the bench heater - Entire Relay PCA 2 - I C Bus - Hot” Lamp Same as PHOTO LAMP TEMP WARNING from Table 11-1 Possible causes of faults are the same as BOX TEMP from Table 11-2 - 2 I C Bus malfunction Gas flow problem through the photometer. Electronic failure of the photometer subsystems Failure or pressure / temperature sensors associated with the photometer Bad/incorrect Span Gas concentration Contamination of the Zero Air supply. Malfunction of the O3 generator. Internal A/D converter problem 183 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.3. USING THE INTERNAL ELECTRONIC STATUS LEDS Several LEDs are located inside the instrument to assist in determining if the calibrators CPU, I2C bus and Relay PCA are functioning properly. 11.3.1. CPU STATUS INDICATOR DS5, a red LED, that is located on upper portion of the motherboard, just to the right of the CPU board, flashes when the CPU is running the main program loop. After power-up, approximately 30 – 60 seconds, DS5 should flash on and off. If characters are written to the front panel display but DS5 does not flash then the program files have become corrupted, contact customer service because it may be possible to recover operation of the calibrator. If after 30 – 60 seconds neither DS5 is flashing and no characters have been written to the front panel display then the CPU is bad and must be replaced. Mother Board P/N 04069 CPU Status LED Figure 11-2: CPU Status Indicator 11.3.2. RELAY PCA STATUS LEDS There are seven LEDs located on the Relay PCA. Some are not used on this model. 11.3.2.1. I2C Bus Watchdog Status LEDs The most important is D1 (see, which indicates the health of the I2C bus. Table 11-4: Relay PCA Watchdog LED Failure Indications LED D1 (Red) Function 2 I C bus Health (Watchdog Circuit) Fault Status Indicated Failure(s) Continuously ON or Continuously OFF Failed/Halted CPU Faulty Mother Board, Keyboard or Relay PCA Faulty Connectors/Wiring between Mother Board, Keyboard or Relay PCA Failed/Faulty +5 VDC Power Supply (PS1) If D1 is blinking, then the other LEDs can be used in conjunction with DIAG Menu Signal I/O to identify hardware failures of the relays and switches on the Relay. 184 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.3.2.2. O3 Status LEDs D9 (Green) – External Zero Air Valve Status D7 (Green) Photometer Meas/Ref Valve Status D2 (Yellow) – Dry (zero) Air Pump Status D15 (Yellow) - Photometer Lamp Heater D16 (Yellow) – O3 Generator Lamp Heater D1 (RED) Watchdog Indicator Figure 11-3: Relay PCA Status LEDS Used for Troubleshooting Table 11-5: Relay PCA Status LED Failure Indications LED FUNCTION SIGNAL I/O PARAMETER ACTIVATED BY VIEW RESULT D2 Yellow Status of AC powered Dry Air Pump ZERO_AIR_PUMP N/A D7 Green Photometer Meas/Ref Valve PHOTO_REF_VALVE N/A D9 Green Status of DC powered Photometer Pump O3-PUMP-ON N/A D15 Yellow Photometer Heater Status PHOTO_LAMP_HEATER PHOTO_LAMP_TEMP D16 Green O3 Generator Heater Status O3_GEN_HEATER O3_GEN_TEMP 05744 Rev B DIAGNOSTIC TECHNIQUE Pump should start /stop Failed pump Failed AC Relay on Relay PCA Failed Relay PCA Faulty AC Power Supply (PS2) Faulty Connectors/Wiring Valve should audibly change states. If not: Failed Valve Failed Relay Drive IC on Relay PCA Failed Relay PCA Faulty +12 VDC Supply (PS2) Faulty Connectors/Wiring Pump should start /stop Failed pump Failed Drive IC on Relay PCA Failed Relay PCA Faulty AC Power Supply (PS2) Faulty Connectors/Wiring Voltage displayed should change. If not: Failed Heater Faulty Temperature Sensor Failed AC Relay Faulty Connectors/Wiring 185 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.4. SUBSYSTEM CHECKOUT The preceding sections of this manual discussed a variety of methods for identifying possible sources of failures or performance problems within the M703E calibrator. In most cases, this includes a list of possible components or subsystems that might be the source of the problem. This section describes how to check individual components or subsystems to determine if which is actually the cause of the problem being investigated. 11.4.1. VERIFY SUBSYSTEM CALIBRATION A good first step when troubleshooting the operation of the M703E calibrator is to verify that its major subsystems are properly calibrated. These are: Test Channel D A conversion (see Section 6.9.2). Gas pressure calibration (see Section 8.3). When optional O3 components are installed, you should also check: Photometer calibration (see Section 8.1). O3 generator calibration (see Section 8.2). 11.4.2. AC MAIN POWER The M703E calibrator’s electronic systems will operate with any of the specified power regimes. As long as system is connected to 100-120 VAC or 220-240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display. Internally, the status LEDs located on the Relay PCA, Motherboard and CPU should turn on as soon as the power is supplied. If they do not, check the circuit breaker built into the ON/OFF switch on the instruments front panel CAUTION SHOULD THE AC POWER CIRCUIT BREAKER TRIP, INVESTIGATE AND CORRECT THE CONDITION CAUSING THIS SITUATION BEFORE TURNING THE CALIBRATOR BACK ON. 186 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.4.3. DC POWER SUPPLY If you have determined that the calibrator’s AC mains power is working, but the unit is still not operating properly, there may be a problem with one of the instrument’s switching power supplies. The supplies can have two faults, namely no DC output, and noisy output. To assist tracing DC Power Supply problems, the wiring used to connect the various printed circuit assemblies and DC Powered components and the associated test points on the relay PCA follow a standard color-coding scheme as defined in the following table. TP1 TP2 TP3 TP4 TP5 TP6 TP7 DGND +5V AGND +15V -15V +12R 12V Figure 11-4: Location of DC Power Test Points on Relay PCA Table 11-6: DC Power Test Point and Wiring Color Codes 05744 Rev B NAME TEST POINT# TP AND WIRE COLOR Dgnd 1 Black +5V 2 Red Agnd 3 Green +15V 4 Blue -15V 5 Yellow +12R 6 Purple +12V 7 Orange 187 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual A voltmeter should be used to verify that the DC voltages are correct per the values in the table below, and an oscilloscope, in AC mode, with band limiting turned on, can be used to evaluate if the supplies are producing excessive noise (> 100 mV p-p). Table 11-7: DC Power Supply Acceptable Levels CHECK RELAY PCA TEST POINTS POWER SUPPLY ASSY VOLTAGE NAME # NAME # PS1 +5 Dgnd 1 +5 PS1 +15 Agnd 3 PS1 -15 Agnd 3 FROM TEST POINT MIN V MAX V 2 4.8 5.25 +15 4 13.5 16V -15V 5 -14V -16V TO TEST POINT PS1 Agnd Agnd 3 Dgnd 1 -0.05 0.05 PS1 Chassis Dgnd 1 Chassis N/A -0.05 0.05 PS2 +12 +12V Ret 6 +12V 7 11.75 12.5 PS2 +12 V ret +12V Ret 6 Dgnd 1 -0.05 0.05 11.4.4. I2C BUS Operation of the I2C bus can be verified by observing the behavior of D1 on the relay PCA & D2 on the valve driver PCA in conjunction with the performance of the front panel display. Assuming that the DC power supplies are operating properly the I2C bus is operating properly if: If D1 on the relay PCA and D2 of the Valve Driver PCA are flashing, or Pressing a key on the front panel results in a change to the display. There is a problem with the I2C bus if Both D1 on the relay PCA and D2 of the Valve Driver PCA are ON/OFF Constantly and pressing a key on the front panel DOES NOT results in a change to the display. If the keyboard interface is working but either of the two Watchdog LEDs is not flashing, the problem may be a wiring issue between the board and the motherboard 11.4.5. KEYBOARD/DISPLAY INTERFACE The front panel keyboard, display and Keyboard Display Interface PCA can be verified by observing the operation of the display when power is applied to the instrument and when a key is pressed on the front panel. Assuming that there are no wiring problems and that the DC power supplies are operating properly: The vacuum fluorescent display is good if on power-up a “-“ character is visible on the upper left hand corner of the display. If there is no “-“ character on the display at power-up and D1 on the Relay PCA or D2 on the valve driver PCA is flashing then the Keyboard/Display Interface PCA is bad. The CPU Status LED, DS5, is flashing, but there is no “-“ character on the display at power-up 188 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator If the calibrator starts operation with a normal display but pressing a key on the front panel does not change the display, then there are three possible problems. One or more of the keys are bad, The interrupt signal between the Keyboard Display interface and the motherboard is broken, or The Keyboard Display Interface PCA is bad. 11.4.6. RELAY PCA The Relay PCA can be most easily checked by observing the condition of the status LEDs located along its upper edge (see Section 11.3.2 and Figure 11-3:Relay PCA Status LEDS Used for Troubleshooting), and using the SIGNAL I/O submenu under the DIAG menu (see Section 11.1.3) to toggle each LED ON or OFF. If D1 on the Relay PCA is flashing and the status indicator for the output in question (Pump power, Heater power, Valve Drive, etc.) toggles properly using the Signal I/O function, then the associated control device on the Relay PCA is bad. Several of the control devices are in sockets and can be easily replaced. The table below lists the control device associated with a particular function. Table 11-8: Relay PCA Control Devices FUNCTION CONTROL DEVICE IN SOCKET UV Lamp Heater Q2 No O3 Gen Heater Q3 No All Valves U5 Yes AC Dry air Pump K1 No DC Photometer Pump U1 No 11.4.7. PHOTOMETER O3 GENERATOR PRESSURE /FLOW SENSOR ASSEMBLY This assembly is only present in calibrators with O3 generator and/or photometer options installed. The pressure/flow sensor PCA, located at the rear of the instrument between the O3 generator and the photometer pump (see Figure 3-3) can be checked with a Voltmeter. The following procedure assumes that the wiring is intact and that the motherboard as well as the power supplies are operating properly: BASIC PCA OPERATION: Measure the voltage across C1 it should be 5 VDC ± 0.25 VDC. If not then the board is bad Measure the voltage between TP2 and TP1 C1 it should be 1o VDC ± 0.25 VDC. If not then the board is bad. 05744 Rev B 189 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual PHOTOMETER PRESSURE SENSOR: 1. Measure the pressure on the inlet side of S1 with an external pressure meter. 2. Measure the voltage across TP4 and TP1. The expected value for this signal should be: EXAMPLE: If the measured pressure is 20 Hg-in-A, the expected voltage level between TP4 and TP1 would be between 2870 mVDC and 3510 mVDC. EXAMPLE: If the measured pressure is 25 Hg-in-A, the expected voltage level between TP4 and TP1 would be between 3533 mVDC and 4318 mVDC. If this voltage is out of range, then either pressure transducer S1 is bad, the board is bad or there is a pneumatic failure preventing the pressure transducer from sensing the absorption cell pressure properly. O3 GENERATOR PRESSURE SENSOR 1. Measure the pressure on the inlet side of S2 with an external pressure meter. 2. Measure the voltage across TP5 and TP1. The expected value for this signal should be: EXAMPLE: If the measured pressure is 25 psig, the expected voltage level between TP4 and TP1 would be between 3470 mVDC and 4245 mVDC. EXAMPLE: If the measured pressure is 30 psig, the expected voltage level between TP4 and TP1 would be between 4030 mVDC and 4930 mVDC. If this voltage is out of range, then either pressure transducer S1 is bad, the board is bad or there is a pneumatic failure preventing the pressure transducer from sensing the absorption cell pressure properly. PHOTOMETER FLOW SENSOR Measure the voltage across TP3 and TP1. With proper flow (800 cc3/min through the photometer), this should be approximately 4.5V (this voltage will vary with altitude). With flow stopped (photometer inlet disconnected or pump turned OFF) the voltage should be approximately 1V. If the voltage is incorrect, the flow sensor S3 is bad, the board is bad or there is a leak upstream of the sensor. 190 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.4.8. MOTHERBOARD 11.4.8.1. A/D Functions The simplest method to check the operation of the A-to-D converter on the motherboard is to use the Signal I/O function under the DIAG menu to check the two A/D reference voltages and input signals that can be easily measured with a voltmeter. 1. Use the Signal I/O function (See Section 11.1.3 and Appendix A) to view the value of REF_4096_MV and REF_GND. If both are within 3 mV of nominal (4096 and 0), and are stable, ±0.5 mV then the basic A/D is functioning properly. If not then the motherboard is bad. 2. Choose a parameter in the Signal I/O function such as PHOTO_LAMP_DRIVE, O3_GEN_TEMP or PHOTO_FLOW. Compare these voltages at their origin (see the interconnect drawing and interconnect list in Appendix D) with the voltage displayed through the signal I/O function. If the wiring is intact but there is a large difference between the measured and displayed voltage (±10 mV) then the motherboard is bad. 11.4.8.2. Test Channel / Analog Outputs Voltage To verify that the analog output is working properly, connect a voltmeter to the output in question and perform an analog output step test as follows: STANDBY Make sure that the M700E is in standby mode. <TST ACT =STANDBY TST> GEN STBY SEQ SETUP X.X O3 SEQ SETUP X.X PRIMARY SETUP MENU CFG CLK PASS MORE 0 Toggle these keys to enter the correct PASSWORD 0 DIAG EXIT ENTER PASSWORD 0 DIAG AOUT Pressing the key under “0%” pause the test. Brackets will appear around the value: EXAMPLE: [20%] Pressing the same key again will resume the test. 05744 Rev B [10%] EXIT ENTR EXIT ANALOG OUTPUT 10% DIAG AOUT ENTR SIGNAL I/O PREV NEXT Performs analog output step test 0% to 100% EXIT SECONDARY SETUP MENU COMM VARS DIAG SETUP X.X SETUP EXIT ANALOG OUTPUT EXIT 191 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual For each of the steps the output should be within 1% of the nominal value listed in the table below except for the 0% step, which should be within 0mV ±2 to 3 mV. Make sure you take into account any offset that may have been programmed into channel (See Section 6.9.1.5). Table 11-9: Analog Output Test Function - Nominal Values Voltage Outputs FULL SCALE OUTPUT OF VOLTAGE RANGE (see Section 6.9.1.3) 100MV 1V 5V 10V STEP % 1 0 0 NOMINAL OUTPUT VOLTAGE 0 0 0 2 20 20 mV 0.2 1 2 3 40 40 mV 0.4 2 4 4 60 60 mV 0.6 3 6 5 80 80 mV 0.8 4 8 6 100 100 mV 1.0 5 10 If one or more of the steps fails to be within these ranges, it is likely that there has been a failure of the either or both of the DACs and their associated circuitry on the motherboard. 11.4.8.3. Status Outputs To test the status output electronics: 1. Connect a jumper between the “D“ pin and the “” pin on the status output connector. 2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status output that is being tested. 3. Connect a voltmeter between the “” pin and the pin of the output being tested (see table below). 4. Under the DIAG SIGNAL I/O menu (See Section11.1.3), scroll through the inputs and outputs until you get to the output in question. 5. Alternately, turn on and off the output noting the voltage on the voltmeter. It should vary between 0 volts for ON and 5 volts for OFF. Table 11-10: 192 Status Outputs Check PIN (LEFT TO RIGHT) STATUS 1 ST_SYSTEM_OK 2 SPARE 3 ST_CAL_ACTIVE 4 ST_DIAG_MODE 5 ST_TEMP_ALARM 6 ST_PRESS_ALARM 7 and 8 SPARE 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.4.8.4. Control Inputs Table 11-11: M703E Control Input Pin Assignments and Corresponding Signal I/O Functions CONNECTOR INPUT CORRESPONDING I/O SIGNAL Top A CONTROL_IN_1 Top B CONTROL_IN_2 Top C CONTROL_IN_3 Top D CONTROL_IN_4 Top E CONTROL_IN_5 Top F CONTROL_IN_6 Bottom G CONTROL_IN_7 Bottom H CONTROL_IN_8 Bottom I CONTROL_IN_9 Bottom J CONTROL_IN_10 Bottom K CONTROL_IN_11 Bottom L CONTROL_IN_12 The control input bits can be tested by applying a trigger voltage to an input and watching changes in the status of the associated function under the SIGNAL I/O submenu: EXAMPLE: to test the “A” control input: 1. Under the DIAG SIGNAL I/O menu (See Section11.1.3), scroll through the inputs and outputs until you get to the output named 0) CONTROL_IN_1. 2. Connect a jumper from the “+” pin on the appropriate connector to the “U” on the same connector. 3. Connect a second jumper from the “” pin on the connector to the “A” pin. 4. The status of 0) CONTROL_IN_1 should change to read “ON”. 05744 Rev B 193 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.4.8.5. Control Outputs Table 11-12: Control Outputs Pin Assignments and Corresponding Signal I/O Functions Check PIN (LEFT TO RIGHT) STATUS 1 CONTROL_OUT_1 2 CONTROL_OUT_2 3 CONTROL_OUT_3 4 CONTROL_OUT_4 5 CONTROL_OUT_5 6 CONTROL_OUT_6 7 CONTROL_OUT_7 8 CONTROL_OUT_8 9 CONTROL_OUT_9 10 CONTROL_OUT_10 11 CONTROL_OUT_11 12 CONTROL_OUT_12 To test the Control Output electronics: 1. Connect a jumper between the “E“ pin and the “” pin on the status output connector. 2. Connect a 1000 ohm resistor between the “+” pin and the pin for the status output that is being tested. 3. Connect a voltmeter between the “” pin and the pin of the output being tested (see Table 11-12). 4. Under the DIAG SIGNAL I/O menu (See Section11.1.3), scroll through the inputs and outputs until you get to the output in question. 5. Alternately, turn on and off the output noting the voltage on the voltmeter. It should vary between 0 volts for ON and 5 volts for OFF. 11.4.9. CPU There are two major types of failures associated with the CPU board: complete failure and a failure associated with the Disk-On Chip on the CPU board. If either of these failures occur, contact the factory. For complete failures, assuming that the power supplies are operating properly and the wiring is intact, the CPU is bad if on powering the instrument: The vacuum fluorescent display shows a dash in the upper left hand corner. The CPU Status LED, DS5, is not flashing. (See Section 11.1.4.1.) There is no activity from the primary RS-232 port on the rear panel even if “? <ret>” is pressed. In some rare circumstances this failure may be caused by a bad IC on the motherboard, specifically U57 the large, 44 pin device on the lower right hand side of the board. If this is true, removing U57 from its socket will allow the instrument to startup but the measurements will be incorrect. If the calibrator stops part way through initialization (there are words on the vacuum fluorescent display) then it is likely that the DOC has been corrupted. 194 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.4.10. RS-232 COMMUNICATIONS 11.4.10.1. General RS-232 Troubleshooting Teledyne Instruments calibrators use the RS-232 communications protocol to allow the instrument to be connected to a variety of computer-based equipment. RS-232 has been used for many years and as equipment has become more advanced, connections between various types of hardware have become increasingly difficult. Generally, every manufacturer observes the signal and timing requirements of the protocol very carefully. Problems with RS-232 connections usually center around four general areas: Incorrect cabling and connectors. See Section 7.1.2 for connector and pin-out information. The BAUD rate and protocol are incorrectly configured. See Section 7.1.3. If a modem is being used, additional configuration and wiring rules must be observed. See Section 7.2 Incorrect setting of the DTE – DCE Switch is set correctly. See Section 7.1.1. Verify that cable (03596) that connects the serial COM ports of the CPU to J12 of the motherboard is properly seated 11.4.10.2. Troubleshooting Calibrator/Modem or Terminal Operation These are the general steps for troubleshooting problems with a modem connected to a Teledyne Instruments calibrator. Check cables for proper connection to the modem, terminal or computer. Check to make sure the DTE-DCE is in the correct position as described in Section 7.1.1. Check to make sure the set up command is correct (See Section 7.2) Verify that the Ready to Send (RTS) signal is at logic high. The M703E sets pin 7 (RTS) to greater than 3 volts to enable modem transmission. Make sure the BAUD rate, word length, and stop bit settings between modem and calibrator match, See Section 7.1.3. Use the RS-232 test function to send “w” characters to the modem, terminal or computer; See Section 7.1.5 Get your terminal, modem or computer to transmit data to the calibrator (holding down the space bar is one way); the green LED should flicker as the instrument is receiving data. Make sure that the communications software or terminal emulation software is functioning properly. NOTE Further help with serial communications is available in a separate manual “RS-232 Programming Notes” Teledyne Instruments part number 013500000. 05744 Rev B 195 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.4.11. TEMPERATURE PROBLEMS Individual control loops are used to maintain the set point of the UV lamp and ozone generator. If any of these temperatures are out of range or are poorly controlled, the M703E will perform poorly. 11.4.11.1. Box / Chassis Temperature The box temperature sensor is mounted to the Motherboard and cannot be disconnected to check its resistance. Rather check the BOX TEMP signal using the SIGNAL I/O function under the DIAG Menu (see Section 11.1.3). This parameter will vary with ambient temperature, but at ~30oC (6-7 above room temperature) the signal should be ~1450 mV. 11.4.11.2. Photometer Sample Chamber Temperature The temperature of the gas in the photometer sample chamber should read approximately 5.0C higher than the box temperature. 11.4.11.3. UV Lamp Temperature There are three possible causes for the UV Lamp temperature to have failed. The UV Lamp heater has failed. Check the resistance between pins 5 and 6 on the six-pin connector adjacent to the UV Lamp on the Optical Bench. It should be approximately 30 Ohms. Assuming that the I2C bus is working and that there is no other failure with the Relay board, the FET Driver on the Relay Board may have failed. Using the PHOTO_LAMP HEATER parameter under the SIGNAL I/O function of the DIAG menu, as described above, turn on and off the UV Lamp Heater (D15 on the relay board should illuminate as the heater is turned on). Check the DC voltage present between pin 1 and 2 on J13 of the Relay Board. If the FET Driver has failed, there will be no change in the voltage across pins 1 and 2. If the FET Driver Q2 checks out OK, the thermistor temperature sensor in the lamp assembly may have failed. Unplug the connector to the UV Lamp Heater/Thermistor PCB, and measure the resistance of the thermistor between pins 5 and 6 of the 6-pin connector. The resistance near the 58oC set point is ~8.1k ohms. 196 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.4.11.4. Ozone Generator Temperature There are three possible causes for the Ozone Generator temperature to have failed. The O3 generator heater has failed. Check the resistance between pins 5 and 6 on the 6-pin connector adjacent to the UV Lamp on the O3 Generator. It should be approximately 5 Ohms. Assuming that the I2C bus is working and that there is no other failure with the Relay board, the FET Driver on the Relay Board may have failed. Using the O3_GEN_HEATER parameter under the SIGNAL I/O function of the DIAG menu, as described above, turn on and off the UV Lamp Heater. Check the DC voltage present between pin 1 and 2 on J14 of the Relay Board. If the FET Driver has failed, there should be no change in the voltage across pins 1 and 2. If the FET Driver checks out OK, the thermistor temperature sensor in the lamp assembly may have failed. Unplug the connector to the Ozone Generator Heater/Thermistor PCB, and measure the resistance of the thermistor between pins 5 and 6 of the 6-pin connector. 11.5. TROUBLESHOOTING THE O3 PHOTOMETER 11.5.1. DYNAMIC PROBLEMS WITH THE O3 PHOTOMETER Dynamic problems are problems, which only manifest themselves when the photometer is measuring O3 concentration gas mixtures. These can be the most difficult and time consuming to isolate and resolve. Since many photometer behaviors that appear to be a dynamic in nature are often a symptom of a seemingly unrelated static problems, it is recommended that dynamic problems not be addressed until all static problems, warning conditions and subsystems have been checked and any problems found are resolved. Once this has been accomplished, the following most common dynamic problems should be checked. 11.5.1.1. Noisy or Unstable O3 Readings at Zero Check for leaks in the pneumatic system as described in Section 10.2 Confirm that the Zero gas is free of Ozone. Confirm that the Source Lamp is fully inserted and that the lamp hold-down thumb- screw is tight. Check for a dirty Absorption Cell and/or pneumatic lines. Clean as necessary as described in Section 10.2 Disconnect the exhaust line from the optical bench (the pneumatic line at the lamp end of the bench) and plug the port in the bench. If readings remain noisy, the problem is in one of the electronic sections of the instrument. If readings become quiet, the problem is in the instrument's pneumatics. 05744 Rev B 197 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.5.1.2. Noisy, Unstable, or Non-Linear Span O3 Readings Check for leaks in the pneumatic systems as described in Section10.2. Check for proper operation of the meas/ref switching valve as described in Section11.5.2. Check for dirty absorption cell and clean or replace as necessary as described in Section 10.2 Check for operation of the A/D circuitry on the motherboard. See Section 11.4.8.1. Confirm the Sample Temperature, Sample Pressure and Sample Flow readings are correct. Check and adjust as required. 11.5.1.3. Slow Response to Changes in Concentration Check for dirty absorption cell and clean or replace as necessary as described in Section 10.2 Check for pneumatic leaks as described in Section 10.2 Check for improper materials in the inlet manifold. The photometer needs 800 cc3/min of gas flow. Make sure that this is accounted for when calculating total required output flow for the calibrator (see Section 3.4.7). 11.5.1.4. The Analog Output Signal Level Does Not Agree With Front Panel Readings Confirm that the recorder offset (see Section 6.9.1.5) is set to zero. Perform an AIO calibration (see Section 6.9.2) and photometer dark calibration (see Section 8.1.4). 11.5.1.5. Cannot Zero Check for leaks in the pneumatic system as described in Section 10.2. Confirm that the Zero gas is free of Ozone. The photometer needs 800 cc3/min of gas flow. Make sure that this is accounted for when calculating total required output flow for the calibrator (see Section 3.4.7). 11.5.1.6. Cannot Span Check for leaks in the pneumatic systems as described in Section 10.2. Check for proper operation of the meas/ref switching valve as described in Section11.5.2. Check for dirty absorption cell and clean or replace as necessary as described in Section 10.2 Check for operation of the A/D circuitry on the motherboard. See Section 11.4.8.1. Confirm the Sample Temperature, Sample Pressure and Sample Flow readings are correct. Check and adjust as required. The photometer needs 800 cc3/min of gas flow. Make sure that this is accounted for when calculating total required output flow for the calibrator (see Section 3.4.7). 198 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.5.2. CHECKING MEASURE / REFERENCE VALVE To check the function of the photometer’s measure / reference valve: 1. Set the calibrator’s front panel display to show the PHOTO REFERENCE test function (see Section 6.1). 2. Follow the instruction in Sections 8.1.1 and 8.1.3.1 for performing a zero point calibration of the photometer. Press XZRO and allow the calibrator to stabilize. 3. Before completing the calibration by pressing the ZERO key, note of the displayed value. 4. Press the final Zero key, then press “NO” when asked, “ARE YOU SURE”. 5. Follow the instruction in Section 8.1.3.2 for performing a span point calibration of the photometer. Press XSPN and allow the calibrator to stabilize. 6. Before completing the calibration by pressing the SPAN key, note of the displayed value of PHOTO REF. If the O3 REF value has decreased by more than 2 mV from its value with Zero-gas, then there is a "cross-port" leak in the m/r valve. 7. Press the final Zero key then press “NO” when asked, “ARE YOU SURE”. 05744 Rev B 199 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.6. TROUBLESHOOTING THE O3 GENERATOR 11.6.1. CHECKING THE UV LAMP POWER SUPPLY NOTE A schematic and physical diagram of the Lamp Power Supply can be found in Appendix D. WARNING Hazardous voltage present - use caution. It is not always possible to determine with certainty whether a problem is the result of the UV Lamp or the Lamp Power Supply, however, the following steps will provide a reasonable confidence test of the Lamp Power Supply. 1. Unplug the cable connector at P1 on the Lamp Power Supply and confirm that +15VDC is present between Pins 1 and 2 on the cable connector. 2. If this voltage is incorrect, check the DC test points on the relay PCA as described in Section 11.4.3. 3. Remove the cover of the photometer and check for the presence of the following voltages on the UV lamp power supply PCA (see Figure 9-21): +4500 mVDC ± 10 mVDC between TP1 and TP4 (grnd) If this voltage is incorrect, either the UV lamp power supply PCA is faulty or the I2C bus is not communicating with the UV lamp power supply PCA. +5VDC between TP3 and TP4 (grnd) If this voltages is les than 4.8 or greater than 5.25 either the 5 VDC power supply or the UV lamp power supply PCA are faulty... If the above voltages check out, it is more likely that a problem is due to the UV Lamp than due to the Lamp Power Supply. Replace the Lamp and if the problem persists, replace the Lamp Power Supply. 200 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.7. TROUBLE SHOOTING THE OPTIONAL O3 GENERATOR The only significant components of the O3 generator that might reasonable malfunction is the power supply assembly for the UV source lamp and the lamp itself. 11.7.1. CHECKING THE UV SOURCE LAMP POWER SUPPLY NOTE A schematic and physical diagram of the Lamp Power Supply can be found in Appendix D. WARNING Hazardous voltage present - use caution. It is not always possible to determine with certainty whether a problem is the result of the UV Lamp or the Lamp Power Supply, however, the following steps will provide a reasonable confidence test of the Lamp Power Supply. 1. Make sure the calibrator is in STANDBY mode. 2. Unplug the cable connector at P1 on the Lamp Power Supply and confirm that +15VDC is present between Pins 1 and 2 on the cable connector. 3. If this voltage is incorrect, check the DC test points on the relay PCA as described in Section 11.4.3. 4. Remove the cover of the photometer and check for the presence of the following voltages on the UV lamp power supply PCA (see Figure 9-21): +800 mVDC ± 10 mVDC between TP1 and TP4 (grnd) If this voltage is incorrect, either the UV lamp power supply PCA is faulty or the I2C bus is not communicating with the UV lamp power supply PCA. +5VDC between TP3 and TP4 (grnd) If this voltages is less than 4.8 or greater than 5.25 either the 5 VDC power supply or the UV lamp power supply PCA are faulty. If the above voltages check out, it is more likely that a problem is due to the UV Lamp than due to the Lamp Power Supply. Replace the Lamp and if the problem persists, replace the Lamp Power Supply. 05744 Rev B 201 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual 11.8. REPAIR PROCEDURES 11.8.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY The critical flow orifice is housed in the flow control assembly (Teledyne Instruments part number: 001760400) located on the top of the optical bench. A sintered filter protects the jewel orifice so it is unusual for the orifice to need replacing, but if it does, or the filter needs replacement please use the following procedure (see the Spare Parts list in Appendix B for part numbers and kits): 1. Turn off power to the calibrator. 2. Locate the assembly to be repaired, see Figure, 3–3. 3. Disconnect the pneumatic connection from the flow assembly. 4. Remove the fitting and the components as shown in the exploded view in Figure 11.6. 5. Replace the o-rings (p/n OR000001) and the sintered filter (p/n FL000001). 6. If replacing the critical flow orifice itself (P/N 000941000), make sure that the side with the colored window (usually red) is facing downstream to the gas flow. 7. Apply new Teflon® tape to the male connector threads 8. Re-assemble in reverse order. Pneumatic Connector, Male 1/8” (P/N FT_70 Spring (P/N HW_20) Sintered Filter (P/N FL_01) Critical Flow Orifice (P/N 000941000) Make sure it is placed with the jewel down) O-Ring (P/N OR_01) Purge Housing (P/N 000850000) Figure 11-5: 202 Critical Flow Restrictor Assembly Disassembly 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator 11.8.2. DISK-ON-CHIP REPLACEMENT PROCEDURE NOTE Printed circuit assemblies (PCAs) are sensitive to electro-static discharges too small to be felt by the human nervous system. Failure to use ESD protection when working with electronic assemblies will void the instrument warranty. See Chapter 12 for more information on preventing ESD damage. Replacing the Disk-on-Chip may be necessary in certain rare circumstances or to load new instrument software. This will cause all of the instrument configuration parameters to be lost. However a backup copy of the operating parameters are stored in a second non-volatile memory and will be loaded into the new the Disk-onChip on power-up. To change the Disk-on-Chip, follow this procedure. 1. Turn off power to the instrument. 2. Fold down the rear panel by loosening the captive Phillips-head screws on each side 3. Locate the Disk-on-Chip in the rightmost socket near the right hand side of the CPU assembly. Remove the IC by gently prying it up from the socket. 4. Reinstall the new Disk-on-Chip, making sure the notch in the end of the chip is facing upward. 5. Close the rear panel and turn on power to the machine. 11.9. TECHNICAL ASSISTANCE If this manual and its trouble-shooting / repair sections do not solve your problems, technical assistance may be obtained from TELEDYNE-API, CUSTOMER SERVICE, 9480 CARROLL PARK DRIVE SAN DIEGO, CALIFORNIA 92121-5201 USA Toll-free Phone: Phone: Fax: Email: Website: 800-324-5190 858-657-9800 858-657-9816 [email protected] http://www.teledyne-api.com/ Before you contact customer service, fill out the problem report form in Appendix C, which is also available online for electronic submission at http://www.teledyne-api.com/forms/. USER NOTES: 05744 Rev B 203 TELEDYNE API General Troubleshooting & Repair of the M703E Calibrator M703E Calibrator Operators Manual USER NOTES: 204 05744 Rev B TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operator’s Manual 12. A PRIMER ON ELECTRO-STATIC DISCHARGE Teledyne Instruments considers the prevention of damage caused by the discharge of static electricity to be extremely important part of making sure that your analyzer continues to provide reliable service for a long time. This section describes how static electricity occurs, why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring. 12.1. HOW STATIC CHARGES ARE CREATED Modern electronic devices such as the types used in the various electronic assemblies of your analyzer, are very small, require very little power and operate very quickly. Unfortunately, the same characteristics that allow them to do these things also make them very susceptible to damage from the discharge of static electricity. Controlling electrostatic discharge begins with understanding how electro-static charges occur in the first place. Static electricity is the result of something called triboelectric charging which happens whenever the atoms of the surface layers of two materials rub against each other. As the atoms of the two surfaces move together and separate, some electrons from one surface are retained by the other. Materials Makes Contact + Materials Separate + + + PROTONS = 3 ELECTRONS = 3 PROTONS = 3 ELECTRONS = 3 NET CHARGE = 0 NET CHARGE = 0 Figure 12-1: PROTONS = 3 ELECTRONS = 2 PROTONS = 3 ELECTRONS = 4 NET CHARGE = -1 NET CHARGE = +1 Triboelectric Charging If one of the surfaces is a poor conductor or even a good conductor that is not grounded, the resulting positive or negative charge cannot bleed off and becomes trapped in place, or static. The most common example of triboelectric charging happens when someone wearing leather or rubber soled shoes walks across a nylon carpet or linoleum tiled floor. With each step, electrons change places and the resulting electro-static charge builds up, quickly reaching significant levels. Pushing an epoxy printed circuit board across a workbench, using a plastic handled screwdriver or even the constant jostling of StyrofoamTM pellets during shipment can also build hefty static charges Table 12-1: Static Generation Voltages for Typical Activities MEANS OF GENERATION 65-90% RH 10-25% RH 1,500V 35,000V Walking across vinyl tile 250V 12,000V Worker at bench 100V 6,000V Poly bag picked up from bench 1,200V 20,000V Moving around in a chair padded with urethane foam 1,500V 18,000V Walking across nylon carpet 05744 Rev B 205 TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operators Manual 12.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE Damage to components occurs when these static charges come into contact with an electronic device. Current flows as the charge moves along the conductive circuitry of the device and the typically very high voltage levels of the charge overheat the delicate traces of the integrated circuits, melting them or even vaporizing parts of them. When examined by microscope the damage caused by electro-static discharge looks a lot like tiny bomb craters littered across the landscape of the component’s circuitry. A quick comparison of the values in Table 12-1 with the those shown in the Table 12-2, listing device susceptibility levels, shows why Semiconductor Reliability News estimates that approximately 60% of device failures are the result of damage due to electro-static discharge. Table 12-2: Sensitivity of Electronic Devices to Damage by ESD DEVICE DAMAGE SUSCEPTIBILITY VOLTAGE RANGE DAMAGE BEGINS OCCURRING AT CATASTROPHIC DAMAGE AT MOSFET 10 100 VMOS 30 1800 NMOS 60 100 GaAsFET 60 2000 EPROM 100 100 JFET 140 7000 SAW 150 500 Op-AMP 190 2500 CMOS 200 3000 Schottky Diodes 300 2500 Film Resistors 300 3000 This Film Resistors 300 7000 ECL 500 500 SCR 500 1000 Schottky TTL 500 2500 Potentially damaging electro-static discharges can occur: Any time a charged surface (including the human body) discharges to a device. Even simple contact of a finger to the leads of a sensitive device or assembly can allow enough discharge to cause damage. A similar discharge can occur from a charged conductive object, such as a metallic tool or fixture. When static charges accumulated on a sensitive device discharges from the device to another surface such as packaging materials, work surfaces, machine surfaces or other device. In some cases, charged device discharges can be the most destructive. A typical example of this is the simple act of installing an electronic assembly into the connector or wiring harness of the equipment in which it is to function. If the assembly is carrying a static charge, as it is connected to ground a discharge will occur. Whenever a sensitive device is moved into the field of an existing electro-static field, a charge may be induced on the device in effect discharging the field onto the device. If the device is then momentarily grounded while within the electrostatic field or removed from the region of the electrostatic field and grounded somewhere else, a second discharge will occur as the charge is transferred from the device to ground. 206 05744 Rev B TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operator’s Manual 12.3. COMMON MYTHS ABOUT ESD DAMAGE I didn’t feel a shock so there was no electro-static discharge: The human nervous system is not able to feel a static discharge of less than 3500 volts. Most devices are damaged by discharge levels much lower than that. I didn’t touch it so there was no electro-static discharge: Electro Static charges are fields whose lines of force can extend several inches or sometimes even feet away from the surface bearing the charge. It still works so there was no damage: Sometimes the damaged caused by electro-static discharge can completely sever a circuit trace causing the device to fail immediately. More likely, the trace will be only partially occluded by the damage causing degraded performance of the device or worse, weakening the trace. This weakened circuit may seem to function fine for a short time, but even the very low voltage and current levels of the device’s normal operating levels will eat away at the defect over time causing the device to fail well before its designed lifetime is reached. These latent failures are often the most costly since the failure of the equipment in which the damaged device is installed causes down time, lost data, lost productivity, as well as possible failure and damage to other pieces of equipment or property. Static Charges can’t build up on a conductive surface: There are two errors in this statement. Conductive devices can build static charges if they are not grounded. The charge will be equalized across the entire device, but without access to earth ground, they are still trapped and can still build to high enough levels to cause damage when discharged. A charge can be induced onto the conductive surface and/or discharge triggered in the presence of a charged field such as a large static charge clinging to the surface of a nylon jacket of someone walking up to a workbench. As long as my analyzer is properly installed, it is safe from damage caused by static discharges: It is true that when properly installed the chassis ground of your analyzer is tied to earth ground and its electronic components are prevented from building static electric charges themselves. This does not prevent discharges from static fields built up on other things, like you and your clothing, from discharging through the instrument and damaging it. 12.4. BASIC PRINCIPLES OF STATIC CONTROL It is impossible to stop the creation of instantaneous static electric charges. It is not, however difficult to prevent those charges from building to dangerous levels or prevent damage due to electro-static discharge from occurring. 12.4.1. GENERAL RULES Only handle or work on all electronic assemblies at a properly set up ESD station. Setting up an ESD safe workstation need not be complicated. A protective mat properly tied to ground and a wrist strap are all that is needed to create a basic anti-ESD workstation. Protective Mat Wrist Stra Ground Point Figure 12-2: 05744 Rev B Basic anti-ESD Work Station 207 TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operators Manual For technicians that work in the field, special lightweight and portable anti-ESD kits are available from most suppliers of ESD protection gear. These include everything needed to create a temporary anti-ESD work area anywhere. Always wear an Anti-ESD wrist strap when working on the electronic assemblies of your analyzer. An anti-ESD wrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels. Anti-ESD wrist straps terminated with alligator clips are available for use in work areas where there is no available grounded plug. Also, anti-ESD wrist straps include a current limiting resistor (usually around one meg-ohm) that protects you should you accidentally short yourself to the instrument’s power supply. Simply touching a grounded piece of metal is insufficient. While this may temporarily bleed off static charges present at the time, once you stop touching the grounded metal new static charges will immediately begin to re-build. In some conditions, a charge large enough to damage a component can rebuild in just a few seconds. Always store sensitive components and assemblies in anti-ESD storage bags or bins: Even when you are not working on them, store all devices and assemblies in a closed anti-Static bag or bin. This will prevent induced charges from building up on the device or assembly and nearby static fields from discharging through it. Use metallic anti-ESD bags for storing and shipping ESD sensitive components and assemblies rather than pink-poly bags. The famous, pink-poly bags are made of a plastic that is impregnated with a liquid (similar to liquid laundry detergent) which very slowly sweats onto the surface of the plastic creating a slightly conductive layer over the surface of the bag. While this layer may equalizes any charges that occur across the whole bag, it does not prevent the build up of static charges. If laying on a conductive, grounded surface, these bags will allow charges to bleed away but the very charges that build up on the surface of the bag itself can be transferred through the bag by induction onto the circuits of your ESD sensitive device. Also, the liquid impregnating the plastic is eventually used up after which the bag is as useless for preventing damage from ESD as any ordinary plastic bag. Anti-Static bags made of plastic impregnated with metal (usually silvery in color) provide all of the charge equalizing abilities of the pink-poly bags but also, when properly sealed, create a Faraday cage that completely isolates the contents from discharges and the inductive transfer of static charges. Storage bins made of plastic impregnated with carbon (usually black in color) are also excellent at dissipating static charges and isolating their contents from field effects and discharges. Never use ordinary plastic adhesive tape near an ESD sensitive device or to close an anti-ESD bag. The act of pulling a piece of standard plastic adhesive tape, such as Scotch® tape, from its roll will generate a static charge of several thousand or even tens of thousands of volts on the tape itself and an associated field effect that can discharge through or be induced upon items up to a foot away. 208 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API A Primer on Eletro-Static Discharge 12.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE 12.4.2.1. Working at the Instrument Rack When working on the analyzer while it is in the instrument rack and plugged into a properly grounded power supply 1. Attach you anti-ESD wrist strap to ground before doing anything else. Use a wrist strap terminated with an alligator clip and attach it to any bare metal portion of the instrument chassis. This will safely connect you to the same ground level to which the instrument and all of its components are connected. 2. Pause for a second or two to allow any static charges to bleed away. 3. Open the casing of the analyzer and begin work. Up to this point, the closed metal casing of your analyzer has isolated the components and assemblies inside from any conducted or induced static charges. 4. If you must remove a component from the instrument, do not lay it down on a non-ESD preventative surface where static charges may lie in wait. 5. Only disconnect your wrist strap after you have finished work and closed the case of the analyzer. 12.4.2.2. Working at an Anti-ESD Work Bench. When working on an instrument of an electronic assembly while it is resting on a anti-ESD work bench 1. Plug you anti-ESD wrist strap into the grounded receptacle of the work station before touching any items on the work station and while standing at least a foot or so away. This will allow any charges you are carrying to bleed away through the ground connection of the workstation and prevent discharges due to field effects and induction from occurring. 2. Pause for a second or two to allow any static charges to bleed away. 3. Only open any anti-ESD storage bins or bags containing sensitive devices or assemblies after you have plugged your wrist strap into the workstation. Lay the bag or bin on the workbench surface. Before opening the container, wait several seconds for any static charges on the outside surface of the container to be bled away by the workstation’s grounded protective mat. 4. Do not pick up tools that may be carrying static charges while also touching or holding an ESD Sensitive Device. Only lay tools or ESD-sensitive devices and assemblies on the conductive surface of your workstation. Never lay them down on any non-ESD preventative surface. 5. Place any static sensitive devices or assemblies in anti-static storage bags or bins and close the bag or bin before unplugging your wrist strap. 6. Disconnecting your wrist strap is always the last action taken before leaving the workbench. 05744 Rev B 209 TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operators Manual 12.4.2.3. Transferring Components from Rack to Bench and Back When transferring a sensitive device from an installed Teledyne Instruments analyzer to an Anti-ESD workbench or back: 1. Follow the instructions listed above for working at the instrument rack and workstation. 2. Never carry the component or assembly without placing it in an anti-ESD bag or bin. 3. Before using the bag or container allow any surface charges on it to dissipate: If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a ground point. If you are at an anti-ESD workbench, lay the container down on the conductive work surface. In either case wait several seconds. 4. Place the item in the container. 5. Seal the container. If using a bag, fold the end over and fastening it with anti-ESD tape. Folding the open end over isolates the component(s) inside from the effects of static fields. Leaving the bag open or simply stapling it shut without folding it closed prevents the bag from forming a complete protective envelope around the device. 6. Once you have arrived at your destination, allow any surface charges that may have built up on the bag or bin during travel to dissipate: Connect your wrist strap to ground. If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a ground point. If you are at a anti-ESD work bench, lay the container down on the conductive work surface In either case wait several seconds 7. Open the container. 12.4.2.4. Opening Shipments from Teledyne Instruments Customer Service. Packing materials such as bubble pack and Styrofoam pellets are extremely efficient generators of static electric charges. To prevent damage from ESD, Teledyne Instruments ships all electronic components and assemblies in properly sealed ant-ESD containers. Static charges will build up on the outer surface of the anti-ESD container during shipping as the packing materials vibrate and rub against each other. To prevent these static charges from damaging the components or assemblies being shipped make sure that you: Always unpack shipments from Teledyne Instruments Customer Service by: 1. Opening the outer shipping box away from the anti-ESD work area 2. Carry the still sealed ant-ESD bag, tube or bin to the anti-ESD work area 3. Follow steps 6 and 7 of Section 12.4.2.3 above when opening the anti-ESD container at the work station 4. Reserve the anti-ESD container or bag to use when packing electronic components or assemblies to be returned to Teledyne Instruments 210 05744 Rev B TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operator’s Manual 12.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service. Always pack electronic components and assemblies to be sent to Teledyne Instruments Customer Service in anti-ESD bins, tubes or bags. WARNING DO NOT use pink-poly bags. NEVER allow any standard plastic packaging materials to touch the electronic component/assembly directly This includes, but is not limited to, plastic bubble-pack, Styrofoam peanuts, open cell foam, closed cell foam, and adhesive tape DO NOT use standard adhesive tape as a sealer. Use ONLY anti-ESD tape 1. Never carry the component or assembly without placing it in an anti-ESD bag or bin. 2. Before using the bag or container allow any surface charges on it to dissipate: If you are at the instrument rack, hold the bag in one hand while your wrist strap is connected to a ground point. If you are at an anti-ESD workbench, lay the container down on the conductive work surface. In either case wait several seconds. 3. Place the item in the container. 4. Seal the container. If using a bag, fold the end over and fastening it with anti-ESD tape. Folding the open end over isolates the component(s) inside from the effects of static fields. Leaving the bag open or simply stapling it shut without folding it closed prevents the bag from forming a complete protective envelope around the device. NOTE If you do not already have an adequate supply of anti-ESD bags or containers available, Teledyne Instruments’ Customer Service department will supply them (see Section 11.9 for contact information). Follow the instructions listed above for working at the instrument rack and workstation. USER NOTES: 05744 Rev B 211 TELEDYNE API A Primer on Eletro-Static Discharge M703E Calibrator Operators Manual USER NOTES: 212 05744 Rev B M703E Calibrator Operator’s Manual TELEDYNE API APPENDIX A – Version Specific Software Documentation APPENDIX A – Version Specific Software Documentation APPENDIX A-1: Model 703E Software Menu Trees, Software Version C.0 APPENDIX A-2: Model 703E Setup Variables Available Via Serial I/O, Software Version C.0 APPENDIX A-3: Model 703E Warnings and Test Measurements Via Serial I/O, Software Version C.0 APPENDIX A-4: Model 703E Signal I/O Definitions, Software Version C.0 APPENDIX A-5: Model M703E Terminal Command Designators, Software Version C.0 05745 Rev C A-1 TELEDYNE API APPENDIX A – Version Specific Software Documentation M703E Calibrator Operator’s Manual USER NOTES: A-2 05745 Rev C 05745 Rev C Figure A-1: APPENDIX A-1: Software Menu Trees, Software Version C.0 M703E Calibrator Operator’s Manual Main Menu TELEDYNE API A-3 APPENDIX A-1: Software Menu Trees, Software Version C.0 TELEDYNE API REF BNCH Leaves O3 generator mode unchanged and returns to previous menu Accepts selected O3 generator mode A-4 EXIT ENTR Press one of these to select mode for O3 generator. CNST MODE O3 Figure A-2: (See Chapter 8 for more information) H :M D DATE ENTR Y EXIT Toggle these keys to set the 2-digit year ENTR 05745 Rev C Only appears when the calibrator is NOT running a programmed sequence EXIT 1 Y MORE See SECONDARY SETUP Menu Toggle this keys to set the month MON TIME :21:29M OFF ON PASS M703E Calibrator Operator’s Manual Toggle these keys to set the day of the month D SETUP X.X CLK Toggle these keys to set the minutes M TIME :21:29M TIME Toggle these keys to set the hour (24-hr clock) H SETUP X.X CPU TYPE & OS REVISION DATE FACTORY CONFIGURATION SAVED (Only appears if INET option is installed) MODEL TYPE AND NUMBER PART NUMBER SERIAL NUMBER SOFTWARE REVISION LIBRARY REVISION iCHIP SOFTWARE REVISION NEXT SETUP PRIMARY SETUP MENU - Basics Initiates automatic Dark Calibration procedure DARK PREV CFG MAIN MENU PHOT Allows calibration of the O3 photometer bench. Requires Password authorization BCAL Causes the drive voltage of the optional O3 generator to 2500 mV. This is used to manually adjust the position of the generators UV Lamp. ADJ See PRIMARY SETUP Menu SEQUENCE Submenu SEQ1 APPENDIX A-1: Software Menu Trees, Software Version C.0 05745 Rev C Figure A-3: M703E Calibrator Operator’s Manual TELEDYNE API PRIMARY SETUP Menu - SEQUENCE CONFIGURATION Submenu A-5 APPENDIX A-1: Software Menu Trees, Software Version C.0 TELEDYNE API A-6 Toggle these keys to set the M700E’s ID code. Figure A-4: APPENDIX A-1: Software Menu Trees, Software Version C.0 05745 Rev C & are only editable when is . Although is editable regardless of the state, do not change the setting for this property. is only editable when is . Menu is inactive while instrument is in mode , Only appears if optional Ethernet PCA is installed. When Ethernet PCA is present COM2 submenu disappears. SECONDARY SETUP Menu - Basic) 5 4 3 2 1 M703E Calibrator Operator’s Manual 05745 Rev C to (see Appendix A) Press to start test 3 2 1 Initiates auto-calibration of all analog outputs Figure A-5: feature is mode 1 Initiates auto-calibration of the analog inputs’ zero and span points Initiates auto-calibration of the selected analog input Sets a voltage offset for the output TELEDYNE API 2 A-7 APPENDIX A-1: Software Menu Trees, Software Version C.0 SECONDARY SETUP Menu; DIAG Submenu – Basics Only occurs if one of the voltage ranges is selected. Manual adjustment menu only appears if either the Menu is inactive while instrument is in M703E Calibrator Operator’s Manual TELEDYNE API A-8 Cycles through default ca points Edits programmed parameters for selected step (See Chapter 8 for further instructions). Figure A-6: Toggle these keys to set the flow rate of the O3 photometer sample gas · · 05745 Rev C Continue pressing to cycle through similar adjustment for... menu is inactive when instrument is in mode. Toggle these keys to set the gas pressure. 1 M703E Calibrator Operator’s Manual SECONDARY SETUP Menu; DIAG Submenu – GAS CONFIGURATION Toggle these keys to adjust parameter. Inserts a new Calibration point Initiates automatic O3 generator calibratin procedure APPENDIX A-1: Software Menu Trees, Software Version C.0 05745 Rev C Figure A-7: M703E Calibrator Operator’s Manual TELEDYNE API PRIMARY SETUP Menu; LVL Submenu – programming LEADS LEVELS (optional) A-9 APPENDIX A-1: Software Menu Trees, Software Version C.0 TELEDYNE API A-10 USER NOTES: APPENDIX A-1: Software Menu Trees, Software Version C.0 05745 Rev C M703E Calibrator Operator’s Manual TELEDYNE API M703E Calibrator Operator’s Manual APPENDIX A-2: Setup Variables For Serial I/O, Software Version C.0 APPENDIX A-2: Setup Variables For Serial I/O, Software Version C.0 Table A-1: M703E Setup Variables, Software Version C.0 M703E SETUP VARIABLES FOR LATEST REVISION SETUP VARIABLE NUMERI C UNITS DEFAULT VALUE VALUE RANGE DESCRIPTION Low Access Level Setup Variables (818 password) 58 PHOTO_LAMP ºC Warnings: 0–100 Photometer lamp temperature set point and warning limits. 0–100 O3 generator lamp temperature set point and warning limits. 56–61 48 O3_GEN_LAMP ºC Warnings: 43–53 O3 concentration range for test channel analog output. O3_CONC_RANGE PPB 500 0.1–20000 O3_PHOTO_BENCH_ONLY — OFF OFF, ON O3 bench control flag. ON turns on pump and switches measure/reference valve only in bench generation mode. ZA_PUMP_ENAB — ON OFF, ON Zero air pump control. ON turns on zero air pump when generating ozone. STD_TEMP ºC 25 0–100 Standard temperature for unit conversions. STD_PRESS “Hg 29.92 15–50 Standard pressure for unit conversions. CLOCK_ADJ Sec./Day 0 -60–60 Time-of-day clock speed adjustment. Medium Access Level Setup Variables (929 password) ENGL, LANGUAGE_SELECT — ENGL SECD, EXTN Selects the language to use for the user interface. Enclose value in double quotes (") when setting from the RS-232 interface. Time until automatically switching out of softwarecontrolled maintenance mode. MAINT_TIMEOUT Hours 2 0.1–100 O3_DWELL Seconds 2.5 0.1–30 O3_SAMPLE Samples 1 1–30 DARK_OFFSET mV 0 -1000–1000 FILT_SIZE Samples 32 1–100 Moving average filter size. FILT_ASIZE Samples 6 1–100 Moving average filter size in adaptive mode. FILT_DELTA PPB 20 1–1000 Absolute concentration difference to trigger adaptive filter. FILT_PCT Percent 5 1–100 Percent concentration difference to trigger adaptive filter. FILT_DELAY Seconds 60 0–60 Delay before leaving adaptive filter mode. — ON OFF, ON ON enables adaptive filter; OFF disables it. PPB/dInHg 0 -200–200 Multiplied by difference between measure and reference pressure and added to concentration. PDELTA_CAL_DUR 2 Minutes 5 0.1–20 Duration of pressure compensation calibration procedure. O3_SLOPE_CONST — 1.0 0.1–10 Constant factor to keep visible slope near 1. O3_SLOPE — 1 0.850–1.150 O3 photometer slope. O3_OFFSET PPB 0 -1000–1000 O3 photometer offset. O3_BCAL_SET PPB 400 0.1–10000 FILT_ADAPT PDELTA_GAIN 05745 Rev C 2 Dwell time after switching measure/reference valve. Number of O3 detector readings to sample. Photometer dark offset for measure and reference readings. Target O3 concentration during bench span calibration. A-11 TELEDYNE API APPENDIX A-2: Setup Variables For Serial I/O, Software Version C.0 M703E Calibrator Operator’s Manual M703E SETUP VARIABLES FOR LATEST REVISION SETUP VARIABLE NUMERI C UNITS DEFAULT VALUE VALUE RANGE O3_PUMP_STARTUP — ON OFF, ON O3_PUMP_MIN_FLOW LPM 0.2 0–1 O3_PUMP_TIMEOUT Seconds 30 1–180 O3_PUMP_PULSE Seconds 0.5 0.1–10 O3 pump power off pulse duration. PHOTO_CYCLE Seconds 10 0.5–30 Photometer lamp temperature control cycle period. PHOTO_PROP — 0.5 0–10 Photometer lamp temperature PID proportional coefficient. PHOTO_INTEG — 0.05 0–10 Photometer lamp temperature PID integral coefficient. PHOTO_DERIV — 0.2 0–10 Photometer lamp temperature PID derivative coefficient. PHOTO_FLOW_SLOPE — 1 0.001–100 O3_DEF_DRIVE mV 0 0–5000 O3_GEN_MODE — BENCH DESCRIPTION O3 pump startup enable. ON enables startup procedure. Minimum flow rate that indicates O3 pump is on. O3 pump startup timeout. Slope term to correct photometer sample flow rate. O3 generator default drive setting. CNST, REF, O3 generator control mode. Enclose value in double quotes (") when setting from the RS-232 interface. BNCH O3_MIN_CONC PPB 25 0–100 O3 generator minimum reliable concentration. Less than this is treated as zero. REF_DELAY Seconds 60 1–300 O3 generator reference feedback control delay. REF_FREQ Seconds 1 1–60 O3 generator reference adjustment frequency. REF_FSIZE Samples 4 1–10 O3 generator reference filter size. REF_INTEG — 0.1 0–10 O3 generator reference PID integral coefficient. REF_DERIV — 0.2 0–10 O3 generator reference PID derivative coefficient. BENCH_DELAY Seconds 120 1–300 O3 generator bench feedback control delay. BENCH_FREQ Seconds 10 1–60 O3 generator bench adjustment frequency. BENCH_FSIZE Samples 3 1–10 O3 generator bench filter size. BENCH_INTEG — 0.2 0–10 O3 generator bench PID integral coefficient. BENCH_DERIV — 0.5 0–10 O3 generator bench PID derivative coefficient. DRIVE_STABIL mV 10 0.1–100 O3 generator drive stability limit to update concentration cache. CACHE_RESOL PPB 2 0.1–20 O3 generator cache un-normalized concentration resolution. O3_LAMP_CYCLE Seconds 2 0.5–30 O3 generator lamp temperature control cycle period. O3_LAMP_PROP 1/DegC 0.2 0–10 O3 generator lamp temperature PID proportional coefficient. O3_LAMP_INTEG Gain 0.01 0–10 O3 generator lamp temperature PID integral coefficient. O3_LAMP_DERIV Gain 0.2 0–10 O3 generator lamp temperature PID derivative coefficient. OUTPUT_FLOW_SLOPE — 1 0.001–100 A-12 Slope term to correct output flow rate. 05745 Rev C TELEDYNE API M703E Calibrator Operator’s Manual APPENDIX A-2: Setup Variables For Serial I/O, Software Version C.0 M703E SETUP VARIABLES FOR LATEST REVISION SETUP VARIABLE NUMERI C UNITS DEFAULT VALUE VALUE RANGE RS232_MODE BitFlag 0 0–65535 DESCRIPTION RS-232 COM1 mode flags. Add values to combine flags. 1 = quiet mode 2 = computer mode 4 = enable security 8 = enable hardware handshaking 32 = enable multi-drop 64 = enable modem 128 = ignore RS-232 line errors 256 = disable XON / XOFF support 512 = disable hardware FIFOs 1024 = enable RS-485 mode 2048 = even parity, 7 data bits, 1 stop bit 4096 = enable command prompt 8192 = even parity, 8 data bits, 1 stop bit 300, 1200, 2400, 4800, BAUD_RATE — 19200 9600, RS-232 COM1 baud rate. Enclose value in double quotes (") when setting from the RS-232 interface. 19200, 38400, 57600, 115200 MODEM_INIT RS232_MODE2 — — “AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0” 0 Any character in the allowed character set. Up to 100 characters long. 0 0–65535 RS-232 COM1 modem initialization string. Sent verbatim plus carriage return to modem on power up or manually. RS-232 COM2 mode flags. (Same settings as RS232_MODE.) 300, 1200, 2400, 4800, BAUD_RATE2 — 19200 9600, RS-232 COM2 baud rate. 19200, 38400, 57600, 115200 MODEM_INIT2 RS232_PASS LINE_DELAY 1 MACHINE_ID 05745 Rev C “AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0” 0 Any character in the allowed character set. Up to 100 characters long. Password 940331 0–999999 ms. 0 0–1000 RS-232 inter-line transmit delay (0=disabled). ID 700 0–9999 Unique ID number for instrument. — RS-232 COM2 modem initialization string. Sent verbatim plus carriage return to modem on power up or manually. RS-232 log on password. A-13 TELEDYNE API APPENDIX A-2: Setup Variables For Serial I/O, Software Version C.0 M703E Calibrator Operator’s Manual M703E SETUP VARIABLES FOR LATEST REVISION SETUP VARIABLE COMMAND_PROMPT NUMERI C UNITS — DEFAULT VALUE VALUE RANGE DESCRIPTION “Cmd> ” Any character in the allowed character set. Up to 100 characters long. RS-232 interface command prompt. Displayed only if enabled with RS232_MODE variable. Enclose value in double quotes (") when setting from the RS-232 interface. NONE, O3 PHOTO MEAS, O3 PHOTO REF, O3 GEN REF, OUTPUT FLOW, REGULATOR PRESSURE, TEST_CHAN_ID — NONE SAMPLE PRESSURE, Diagnostic analog output ID. Enclose value in double quotes (") when setting from the RS-232 interface. SAMPLE FLOW, SAMPLE TEMP, PHOTO LAMP TEMP, O3 LAMP TEMP, CHASSIS TEMP, O3 PHOTO CONC PASS_ENABLE — ON OFF, ON DEF_CC_OUTPUT — “000000000 000” Any string of exactly 12 characters consisting of the digits 0 and 1 only. PHOTO_LAMP_POWER mV 4500 0–5000 LAMP_PWR_ENABLE — ON OFF, ON LAMP_PWR_PERIOD Hours 24 0.01–1000 ON enables passwords. OFF disables them. Default contact closure output pattern when not executing a sequence. Enclose value in double quotes (") when setting from the RS-232 interface. Photometer lamp power setting. ON enables photometer lamp power cycling. OFF disables it. Photometer lamp power cycling period. LAMP_OFF_DELAY Seconds 0.1 0.02–5 Length of time photometer lamp is turned off. DET_VALID_DELAY Seconds 20 1–300 Delay until valid concentration is computed. REF_SDEV_LIMIT mV 3 0.1–100 PATH_LENGTH cm 41.96 0.01–99.999 BOX_SET ºC Warnings: Photometer reference standard deviation must be below this limit to switch out of startup mode. Photometer detector path length. 30 0–100 Internal box temperature set point and warning limits. 5–45 GAS_MOL_WEIGHT SERIAL_NUMBER MolWt — 32 1–99.999 “00000000 ” Any character in the allowed character set. Up to 100 characters long. Molar mass of sample gas for computing concentrations by weight instead of volume. Unique serial number for instrument. HIGH, DISP_INTENSITY — HIGH MED, LOW, Front panel display intensity. Enclose value in double quotes (") when setting from the RS-232 interface. DIM A-14 05745 Rev C TELEDYNE API M703E Calibrator Operator’s Manual APPENDIX A-2: Setup Variables For Serial I/O, Software Version C.0 M703E SETUP VARIABLES FOR LATEST REVISION SETUP VARIABLE NUMERI C UNITS DEFAULT VALUE VALUE RANGE I2C_RESET_ENABLE — ON OFF, ON DESCRIPTION 2 I C bus automatic reset enable. Time-of-day clock format flags. Enclose value in double quotes (“) when setting from the RS-232 interface. “%a” = Abbreviated weekday name. “%b” = Abbreviated month name. “%d” = Day of month as decimal number (01 – 31). “%H” = Hour in 24-hour format (00 – 23). “%I” = Hour in 12-hour format (01 – 12). CLOCK_FORMAT — “TIME=%H: %M:%S” Any character in the allowed character set. Up to 100 characters long. “%j” = Day of year as decimal number (001 – 366). “%m” = Month as decimal number (01 – 12). “%M” = Minute as decimal number (00 – 59). “%p” = A.M./P.M. indicator for 12-hour clock. “%S” = Second as decimal number (00 – 59). “%w” = Weekday as decimal number (0 – 6; Sunday is 0). “%y” = Year without century, as decimal number (00 – 99). “%Y” = Year with century, as decimal number. “%%” = Percent sign. Factory option flags. Add values to combine options. FACTORY_OPT — 0 0–65535 1024 = enable software-controlled maintenance mode 2048 = enable Internet option 3 4096 = enable switch-controlled maintenance mode 1 Dasibi emulation version only. 2 Experimental. 3 iChip option. 05745 Rev C A-15 TELEDYNE API APPENDIX A-3: Warnings and Test Functions, Software Version C.0 M703E Calibrator Operator’s Manual APPENDIX A-3: Warnings and Test Functions, Software Version C.0 Table A-2: 1 M703E Warning Messages, Software Version C.0 NAME 1 MESSAGE TEXT WSYSRES SYSTEM RESET DESCRIPTION Instrument was power-cycled or the CPU was reset. WDATAINIT DATA INITIALIZED WCONFIGINIT CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased. WPHOTOLTEMP PHOTO LAMP TEMP WARNING Photometer lamp temperature outside of warning limits specified by PHOTO_LAMP variable. WO3GENTEMP O3 GEN LAMP TEMP WARNING O3 generator lamp temperature outside of warning limits specified by O3_GEN_LAMP variable. WPHOTOREF PHOTO REFERENCE WARNING Photometer reference reading less than 2500 mV or greater than 4999 mV. WLAMPSTABIL PHOTO LAMP STABILITY WARNING Photometer lamp reference step changes occur more than 25% of the time. WO3GENREF O3 GEN REFERENCE WARNING O3 reference detector drops below 50 mV during reference feedback O3 generator control. WO3PUMP O3 PUMP WARNING O3 pump failed to turn on within timeout period specified by O3_PUMP_TIMEOUT variable. WBOXTEMP BOX TEMP WARNING Chassis temperature outside of warning limits specified by BOX_SET variable. WREARBOARD REAR BOARD NOT DET WRELAYBOARD RELAY BOARD WARN Firmware is unable to communicate with the relay board. WLAMPDRIVER LAMP DRIVER WARN Firmware is unable to communicate with either the O3 generator or photometer lamp I2C driver chip. WFRONTPANEL FRONT PANEL WARN Firmware is unable to communicate with the front panel. WANALOGCAL ANALOG CAL WARNING Data storage was erased. Rear board was not detected during power up. The A/D or at least one D/A channel has not been calibrated. The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”. A-16 05745 Rev C TELEDYNE API M703E Calibrator Operator’s Manual Table A-3: TEST FUNCTION NAME 1 APPENDIX A-3: Warnings and Test Functions, Software Version C.0 M703E Test Functions, Software Version C.0 MESSAGE TEXT DESCRIPTION ACTCONC ACT=GENERATE 37 PPB O3 TARGCONC TARG=GENERATE 100 PPB O3 OUTPUTFLOW OUTPUT FLOW=7.3 LPM REGPRESS REG PRESSURE=20.1 PSIG BOXTEMP BOX TEMP=31.2 C O3GENREF O3 GEN REF=1000.0 MV O3 generator reference detector reading. O3GENDRIVE O3 GEN DRIVE=800.0 MV O3 generator lamp drive output. Actual concentration being generated, computed from realtime inputs. Target concentration to generate. Output flow rate (computed from regulator pressure). Regulator pressure. Internal chassis temperature. O3GENTEMP O3 LAMP TEMP=49.7 C PHOTOMEAS PHOTO MEASURE=2998.8 MV Photometer detector measure reading. PHOTOREF PHOTO REFERENCE=3000.0 MV Photometer detector reference reading. O3 generator lamp temperature. PHOTOFLOW PHOTO FLOW=0.2978 LPM Photometer sample flow rate. PHOTOLTEMP PHOTO LAMP TEMP=52.6 C Photometer lamp temperature. PHOTOSPRESS PHOTO SPRESS=29.9 IN-HG-A Photometer sample pressure. PHOTOSTEMP PHOTO STEMP=31.8 C Photometer sample temperature. PHOTOSLOPE PHOTO SLOPE=1.000 Photometer slope computed during zero/span bench calibration. PHOTOOFFSET PHOTO OFFSET=0.0 PPB Photometer offset computed during zero/span bench calibration. PHOTOSTABIL 2 PHOTO STABIL=0.1 PPB Photometer concentration stability (standard deviation of 25 bench concentration samples taken 10 seconds apart). TESTCHAN TEST=2753.9 MV CLOCKTIME TIME=14:48:01 Value output to TEST_OUTPUT analog output, selected with TEST_CHAN_ID variable. Current instrument time of day clock. 1 The name is used to request a message via the RS-232 interface, as in “T BOXTEMP”. 2 O3 photometer stability measurement option. 05745 Rev C A-17 TELEDYNE API APPENDIX A-3: Warnings and Test Functions, Software Version C.0 M703E Calibrator Operator’s Manual USER NOTES: A-18 05745 Rev C TELEDYNE API M703E Calibrator Operator’s Manual APPENDIX A-4: Signal I/O Definitions, Software Version C.0 APPENDIX A-4: Signal I/O Definitions, Software Version C.0 Table A-4: M703E Signal I/O Definitions, Software Version C.0 M703E I/O Signal List for Latest Revision Bit or Channel Number Signal Name Description U11, J1004, control inputs, pins 1-6 = bits 0-5, read, default I/O address 321 hex CONTROL_IN_1 – CONTROL_IN_6 0–5 0 = input asserted 1 = de-asserted 6–7 Always 1 U14, J1006, control inputs, pins 1-6 = bits 0-5, read, default I/O address 325 hex CONTROL_IN_7 – CONTROL_IN_12 0–5 0 = input asserted 1 = de-asserted 6–7 Always 1 U17, J1008, control outputs, pins 1-8 = bits 0-7, write, default I/O address 321 hex CONTROL_OUT_1 – CONTROL_OUT_8 0–7 0 = output asserted 1 = de-asserted U21, J1008, control outputs, pins 9-12 = bits 0-3, write, default I/O address 325 hex CONTROL_OUT_9 – CONTROL_OUT_12 0–3 0 = output asserted 1 = de-asserted U7, J108, internal inputs, pins 9-16 = bits 0-7, read, default I/O address 322 hex 0–7 Spare U8, J108, internal outputs, pins 1-8 = bits 0-7, write, default I/O address 322 hex 0–7 Spare U24, J1017, A status outputs, pins 1-8 = bits 0-7, write, default I/O address 323 hex ST_SYSTEM_OK 0 0 = system OK 1 = any alarm condition or in diagnostics mode 1 ST_CAL_ACTIVE 2 Spare 0 = executing sequence 1 = not executing sequence ST_DIAG_MODE 3 0 = in diagnostic mode 1 = not in diagnostic mode ST_TEMP_ALARM 4 0 = any temperature alarm 1 = all temperatures OK ST_PRESS_ALARM 5 0 = any pressure alarm 1 = all pressures OK 6-7 Spare U27, J1018, B status outputs, pins 1-8 = bits 0-7, write, default I/O address 324 hex 0-7 Spare Relay board digital output (PCF8575), write, default I2C address 44 hex RELAY_WATCHDOG 0 Alternate between 0 and 1 at least every 5 seconds to keep relay board active ZERO_AIR_PUMP 1 0 = pump on for zero air 1 = off 2–5 05745 Rev C Spare A-19 TELEDYNE API M703E Calibrator Operator’s Manual APPENDIX A-4: Signal I/O Definitions, Software Version C.0 M703E I/O Signal List for Latest Revision Signal Name Bit or Channel Number PHOTO_REF_VALVE 6 ZA_SHUTOFF_VALVE 7 Description 0 = photometer valve in reference position 1 = measure position 0 = open zero air shutoff valve 1 = close O3_PUMP_ON 8 0 = pump on for photometer to measure O3 1 = off 9–13 PHOTO_LAMP_HEATER Spare 0 = O3 photometer lamp heater on 14 1 = off O3_GEN_HEATER 0 = O3 generator lamp heater on 15 1 = off 2 2 Front panel I C keyboard, default I C address 4E hex MAINT_MODE 5 (input) 0 = maintenance mode 1 = normal mode LANG2_SELECT 6 (input) SEQUENCE_LED 8 (output) 0 = select second language 1 = select first language (English) 0 = sequence LED on (executing sequence) 1 = off AUTO_TIMER_LED 9 (output) 0 = automatic timer LED on (automatic sequence timer enabled) 1 = off FAULT_LED 10 (output) 0 = fault LED on 1 = off AUDIBLE_BEEPER 14 (output) 0 = beeper on (for diagnostic testing only) 1 = off Rear board primary MUX analog inputs PHOTO_DET 0 Photometer detector reading O3_GEN_REF_DET 1 O3 generator reference detector reading 2 Spare 3 Photometer sample pressure 4 Temperature MUX REGULATOR_PRESS 5 Regulator pressure PHOTO_FLOW 6 Photometer flow PHOTO_SAMP_PRES 7–8 REF_4096_MV Spare 9 4.096V reference from MAX6241 10-11 OUTPUT_FLOW Spare 12 Output flow 13 Spare 14 DAC loopback MUX REF_GND 15 Ground reference BOX_TEMP 0 Internal box temperature PHOTO_SAMP_TEMP 1 Photometer sample temperature Rear board temperature MUX analog inputs A-20 05745 Rev C TELEDYNE API M703E Calibrator Operator’s Manual APPENDIX A-4: Signal I/O Definitions, Software Version C.0 M703E I/O Signal List for Latest Revision Signal Name Bit or Channel Number PHOTO_LAMP_TEMP 2 Photometer lamp temperature O3_GEN_TEMP 3 O3 generator lamp temperature 4–7 Description Spare Rear board DAC MUX analog inputs DAC_CHAN_1 0 DAC channel 0 loopback DAC_CHAN_2 1 DAC channel 1 loopback DAC_CHAN_3 2 DAC channel 2 loopback DAC_CHAN_4 3 DAC channel 3 loopback CONC_OUT_1 0 Concentration output #1 CONC_OUT_2 1 Concentration output #2 2 Spare 3 Test measurement output Rear board analog outputs TEST_OUTPUT I2C analog output (AD5321), default I2C address 18 hex PHOTO_LAMP_DRIVE 0 O3 photometer lamp drive (0–5V) 2 I C analog output (AD5321), default I2C address 1A hex O3_GEN_DRIVE 05745 Rev C 0 O3 generator lamp drive (0–5V) A-21 TELEDYNE API APPENDIX A-5: Terminal Command Designators, Software Version C.0 M703E Calibrator Operator’s Manual APPENDIX A-5: Terminal Command Designators, Software Version C.0 Table A-5: COMMAND Terminal Command Designators, Software Version C.0 ADDITIONAL COMMAND SYNTAX ? [ID] LOGON [ID] Display help screen and commands list password Establish connection to instrument LOGOFF [ID] T [ID] W [ID] C [ID] D [ID] V [ID] DESCRIPTION Terminate connection to instrument SET ALL|name|hexmask Display test(s) LIST [ALL|name|hexmask] [NAMES|HEX] Print test(s) to screen name Print single test CLEAR ALL|name|hexmask Disable test(s) SET ALL|name|hexmask Display warning(s) LIST [ALL|name|hexmask] [NAMES|HEX] Print warning(s) name Clear single warning CLEAR ALL|name|hexmask Clear warning(s) ZERO|LOWSPAN|SPAN [1|2] Enter calibration mode ASEQ number Execute automatic sequence COMPUTE ZERO|SPAN Compute new slope/offset EXIT Exit calibration mode ABORT Abort calibration sequence LIST Print all I/O signals name[=value] Examine or set I/O signal LIST NAMES Print names of all diagnostic tests ENTER name Execute diagnostic test EXIT Exit diagnostic test RESET [DATA] [CONFIG] [exitcode] Reset instrument LIST Print setup variables name[=value [warn_low [warn_high]]] Modify variable name="value" Modify enumerated variable CONFIG Print instrument configuration MAINT ON|OFF Enter/exit maintenance mode MODE Print current instrument mode The command syntax follows the command type, separated by a space character. Strings in [brackets] are optional designators. The following key assignments also apply. Table A-6: Terminal Key Assignments, Software Version C.0 TERMINAL KEY ASSIGNMENTS ESC Abort line CR (ENTER) Execute command Ctrl-C Switch to computer mode COMPUTER MODE KEY ASSIGNMENTS A-22 LF (line feed) Execute command Ctrl-T Switch to terminal mode 05745 Rev C TELEDYNE API APPENDIX B: Spare Parts List Model 703E Calibrator Operator’s Manual APPENDIX B: Spare Parts List NOTE Use of replacement parts other than those supplied by API may result in non-compliance with European standard EN 61010-1. 05834 - LIST, SPARE PARTS, M703E 05863 - LIST, RECOMMENDED SPARES STOCKING LEVELS, M703E 05746 Rev B B-1 TELEDYNE API APPENDIX B: Spare Parts List Model 703E Calibrator Operator’s Manual THIS PAGE IS INTENTIONALLY LEFT BLANK B-2 05746 Rev B Spare Parts List M703E Part Number 000940100 006120100 022710000 040010000 040030700 040300110 040300210 041200000 041200200 041440000 042010000 042580000 042900100 045230100 046740000 049290000 050700500 052400000 052910100 055220000 055730000 056420000 056430000 057360000 057430000 057660000 057670000 058021400 058110000 058330000 058330100 062870000 063720100 064130000 CN0000073 CP0000026 DS0000025 FL0000001 FL0000003 FL0000020 FM0000004 FM0000005 FM0000006 HW0000005 HW0000020 Description CD, ORIFICE, .003 GREEN ASSY, OZONE GEN LAMP (BIR) (OP5) ABSORPTION TUBE, QUARTZ, M400A/E (KB) ASSY, FAN REAR PANEL, E SERIES PCA, PRESS SENSORS (2X), 700E PHOTO OPT ASSY, CONFIG PLUG, 100-115V, M400E/M703E ASSY, CONFIG PLUG, 220-240V, M400E/M703E PCA, DET PREAMP w/OP20, M400E/M700E/M703 PCA, DET PREAMP w/OP20 M700E/ M400E/M703 PCA, DC HTR/TEMP, BENCH, M400E/M70XE ASSY, SAMPLE THERMISTOR, M400E PCA, KEYBOARD, E-SERIES, W/V-DETECT PROGRAMMED FLASH, E SERIES PCA, RELAY CARD, E SERIES ASSY, PUMP, 12VDC, M460M/M700E/M465L CLIP, THERMISTOR HOLDER KIT, RELAY BD M703E CONFIGURATION ASSY, BENCH UV LAMP, (BIR), CR * ASSY, OPTICAL BENCH, M400E/M703E ASSY, VALVE W/CONN, VA 59 ASSY, REGULATOR, FILTERS, 20LPM M703E ASSY, FLOW CNTRL,5LPM, DILUTION, M703E ASSY, FLOW CONTROL, PHOTO REF, M703E ASSY, 3/8" VENT ADAPTER, M700E MANUAL, OPERATORS, M703E ASSY, DFU FILTER, M703E ASSY, CARBON SCRUBBER, M703E PCA, E-SERIES MTHRBRD, M700E, GEN 5-I ASSY, EXPENDABLES AKIT, M703E* ASSY, INT PUMP, 115V, M703E ASSY, INT PUMP, 230V, M703E CPU, PC-104, VSX-6150E, ICOP *(KB) DOM, w/SOFTWARE, M703E * ASSY, DC HEATER/THERM PCA, O3 GEN POWER ENTRY, 120/60 (KB) CPU MOD, AR-B1320, PC/104, 38 (KB) DISPLAY, E SERIES (KB) FILTER, SS FILTER, DFU (KB) CARBON FILTER, DAU, 000 GRADE *(KB) FLOWMETER (KB) FLOW RESTRICTOR, 5000-1/4-10000CCM FLOW RESTRICTOR, 5000-1/4-5000CCM FOOT SPRING 05834J - M703E Spare Parts List (DCN 5480) Page 1 of 2 07/15/09 Spare Parts List M703E Part Number HW0000380 HW0000453 KIT000253 KIT000254 KIT000289 KIT000290 OP0000014 OP0000031 OR0000001 OR0000016 OR0000026 OR0000034 OR0000039 OR0000048 OR0000077 OR0000089 RL0000015 SW0000051 SW0000059 SW0000060 VA0000014 VA0000060 WR0000008 Description HANDLE, CARRYING, 9.25", BLK * SUPPORT, CIRCUIT BD, 3/16" ICOP ASSY & TEST, SPARE PS37, E SERIES ASSY & TEST, SPARE PS38, E SERIES KIT, UV LAMP P/S PCA, 041660100 KIT, UV LAMP P/S PCA, 041660500 QUARTZ DISC, .75 DIA X 1/16", M400A (KB) WINDOW, QUARTZ, 1/2"DIA, .063" THICK (KB ORING, 2-006VT * ORING, 2-120V ORING, 2-110 S604-70 ORING, 2-011V FT10 ORING, 2-012V ORING, 2-112S ORING, 2-018V ORING, 2-016V RELAY, DPDT, (KB) SWITCH, POWER CIRC BREAK VDE/CE, w/RG(KB PRESSURE SENSOR, 0-15 PSIA, ALL SEN PRESSURE SENSOR, 0-100 PSIG, ALL SEN700e REGULATOR CHECK VALVE, B, 1/4" TUBE FITTINGS POWER CORD, 10A 05834J - M703E Spare Parts List (DCN 5480) Page 2 of 2 07/15/09 Recommended Spare Parts Stocking Levels M703E Recommended Spare Parts Stocking Level: Standard Part Number 006120100 022710000 058330000 058330100 040010000 040030700 041200000 041200200 041440000 041660100 041660500 062870000 042010000 042580000 045230100 046740000 052400000 056420000 056430000 058021400 DS0000025 KIT000253 KIT000254 Description ASSY, OZONE GEN LAMP ABSORPTION TUBE, QUARTZ ASSY, INT PUMP, 115V/60Hz ASSY, INT PUMP, 230V/50Hz ASSY, FAN, REAR PANEL PCA, PRESS SENSORS PHOTO OPT PCA, DET. PREAMP w/OP20, BENCH PCA, DET. PREAMP w/OP20, O3 GEN PCA, DC HEATER/TEMP SENSOR PCA, UV POWER SUPPLY, O3 GEN, PCA, UV POWER SUPPLY, OPT BENCH CPU, PC-104, VSX-6150E, ICOP *(KB) THERMISTOR ASSEMBLY KEYBOARD PCA, RELAY CARD ASSY, PUMP, 12 VDC ASSY, UV LAMP BENCH ASSY, FLOW CONTROL, DILUTION ASSY, FLOW CONTROL, PHOTO REF PCA, E-SERIES MOTHERBOARD, GEN 5-I DISPLAY 2-5 Units 6-10 11-20 21-30 1 1 2 2 4 1 1 1 2 2 1 1 2 1 1 2 4 4 1 1 4 1 1 1 4 1 2 4 8 1 1 8 8 2 2 8 2 2 2 8 2 4 1 4 2 2 2 2 2 2 1 KIT, SPARE, PS37, PWR SUPPLY,+5V,+15V,-15V KIT, SPARE, PS38, POWER SUPPLY, 12V 05863D - M703E RSSL (DCN 5480) Printed documents are UNCONTROLLED 1 1 2 1 1 1 1 1 1 07/15/09 THIS PAGE IS INTENTIONALLY LEFT BLANK Model M703E Calibrator Operator’s Manual Warranty/Repair Questionnaire Model 703E CUSTOMER:_______________________________ PHONE: _____________________________________ CONTACT NAME: __________________________ FAX NO. _____________________________________ SITE ADDRESS:____________________________________________________________________________ MODEL TYPE: ______________ SERIAL NO.:_________________ FIRMWARE REVISION: _____________ Are there any failure messages? _______________________________________________________________ _________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ ________________________________________________________________________ (Continue on back if necessary) PLEASE COMPLETE THE FOLLOWING TABLE: PARAMETER RECORDED VALUE ACCEPTABLE VALUE ACT PPB 1% OF TARG TARG PPB 50 – 1000 PPB OUTPUT FLOW LPM 2 – 5 LPM REG PRESSURE PSIG 15 ± 2 PSIG @ 5 LPM BOX TEMP ºC 20 – 35 ºC O3 GEN REF mV 0 – 5000 mV O3 GEN DRIVE mV 0 – 5000mV O3 LAMP TEMP ºC 48 ± 1 ºC PHOTO MEASURE mV 2500 – 4700 mV PHOTO REFERENCE mV 2500 – 4700 mV PHOTO FLOW LPM 0.720 – 0.880 LPM PHOTO LAMP TEMP PHOTO SPRESS PHOTO STEMP ºC IN-HG-A ºC PHOTO SLOPE PHOTO OFFSET 58 ± 1 ºC -1” AMBIENT IN-HG-A 25 – 48ºC 1 ± 0.15 PPB 0 ± 10 PPB Depending on options installed, not all test parameters shown below will be available in your calibrator) 1 If ozone generator option installed. 2 If photometer option installed. 3 i f permeation tube installed. What is measured photometer flow rate ____________________________________________________ cc3/min What is measured O3 generator flow rate? _________________________________________________ cc3/min What is the photo reference value while generating SPAN: __________________ ZERO: __________________ TELEDYNE API CUSTOMER SERVICE EMAIL: [email protected] PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 05747 Rev B FAX: (858) 657-9816 C-1 Model M703E Calibrator Operator’s Manual Warranty/Repair Questionnaire Model 703E What are the failure symptoms? ________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ What tests have you done trying to solve the problem? ______________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ Thank you for providing this information. Your assistance enables Teledyne Instruments to respond faster to the problem that you are encountering. OTHER NOTES: ____________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ __________________________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ _______________________________________________________________________________ TELEDYNE API CUSTOMER SERVICE EMAIL: [email protected] PHONE: (858) 657-9800 TOLL FREE: (800) 324-5190 C-2 FAX: (858) 657-9816 05747 Rev B TELEDYNE API Model 703E Calibrator Operator’s Manual APPENDIX D: Diagrams and Schematics APPENDIX D: Diagrams and Schematics Table D-1: List of Included Diagrams and Schematics Document # Document Title 05826 Interconnect Drawing M703E 05827 Interconnect List M703E 04420 SCH, PCA 04120, UV DETECTOR, M400E 04422 SCH, PCA 04144, DC HEATER/TEMP SENSOR 04421 SCH, PCA 04166, UV LAMP POWER SUPPLY, M400E 04259 SCH, PCA 04258, KEYBOARD, E-SERIES 04354 SCH, PCA 04003, Pressure/Flow Transducer Interface 04395 SCH, PCA 04394, INTRFC,ETHERNET,E-SERIES 04524 SCH, PCA 04523, RELAY CARD, M100E/M200E/M400E 05703 SCH, PCA 05702, MTHERBRD, E-SER, GEN-4 05748 Rev B D-1 TELEDYNE API APPENDIX D: Diagrams and Schematics Model 703E Calibrator Operator’s Manual THIS PAGE IS INTENTIONALLY LEFT BLANK D-2 05748 Rev B TELEDYNE API Model 703E Calibrator Operator’s Manual APPENDIX D: Diagrams and Schematics APPENDIX D: Diagrams and Schematics Table D-1: List of Included Diagrams and Schematics Document # Document Title 05826 Interconnect Drawing M703E 05827 Interconnect List M703E 04420 SCH, PCA 04120, UV DETECTOR, M400E 04422 SCH, PCA 04144, DC HEATER/TEMP SENSOR 04421 SCH, PCA 04166, UV LAMP POWER SUPPLY, M400E 04259 SCH, PCA 04258, KEYBOARD, E-SERIES 04354 SCH, PCA 04003, Pressure/Flow Transducer Interface 04395 SCH, PCA 04394, INTRFC,ETHERNET,E-SERIES 04524 SCH, PCA 04523, RELAY CARD, M100E/M200E/M400E 05703 SCH, PCA 05702, MTHERBRD, E-SER, GEN-4 05748 Rev B D-1 TELEDYNE API APPENDIX D: Diagrams and Schematics Model 703E Calibrator Operator’s Manual THIS PAGE IS INTENTIONALLY LEFT BLANK D-2 05748 Rev B 05827 Revision A J8 J8 J8 J8 J8 J8 J8 045230100 045230100 045230100 045230100 045230100 045230100 045230100 J19 J19 J27 J27 J27 J27 J27 J27 J14 3 4 5 6 9 3 4 5 6 9 2 4 6 Date 1/10/2007 041440000 041440000 041440000 041440000 042010000 042010000 041440100 041440100 041440100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 040690100 PS0000037 PS0000037 PS0000037 PS0000037 PS0000037 PS0000038 PS0000038 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 057020400 SW0000051 SW0000051 SW0000051 052590000 PS0000038 PS0000038 PS0000038 PS0000037 PS0000037 PS0000037 045230100 045230100 045230100 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 04258 CONNECTION TO PN Lamp HTR/Thrm Lamp HTR/Thrm Lamp HTR/Thrm Lamp HTR/Thrm Sample Therm Sample Therm O3 Gen HTR/Therm O3 Gen HTR/Therm O3 Gen HTR/Therm Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard PS1 (+5, ±15) PS1 (+5, ±15) PS1 (+5, ±15) PS1 (+5, ±15) PS1 (+5, ±15) PS2 (+12) PS2 (+12) Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Motherboard Power Switch Power Switch Shield Chassis PS2 (+12) PS2 (+12) PS2 (+12) PS1 (+5, ±15) PS1 (+5, ±15) PS1 (+5, ±15) Relay Board Relay Board Relay Board Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Keyboard/Interface Assembly Checked KV PRINTED DOCUMENTS ARE FOR REFERENCE ONLY 1 2 6 13 7 14 12 5 2 1 2 4 5 6 7 8 7 2 5 6 10 1 2 3 4 5 6 7 8 10 L N L N L N L N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pin M703E Interconnect Listing 045230100 045230100 057020400 057020400 057020400 057020400 057020400 057020400 045230100 CN3 CN3 CN3 CN3 CN3 CN4 CN4 CN4 CN4 CN4 CN5 CN5 CN5 J2 J2 J2 J2 J2 042580000 042580000 042580000 042580000 042580000 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 CP_26 J7 J7 J7 J7 J7 J7 J7 J7 J7 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 CN1 J/P 045230100 045230100 045230100 045230100 045230100 045230100 045230100 045230100 045230100 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 CN0000073 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 DS_9 CONNECTION FROM Assembly PN 007290000 CBL, KEYBOARD/DISPLAY D7 Display D6 Display D5 Display D4 Display D3 Display D2 Display D1 Display D0 Display DISP WRITE Display DGND Display Spare Display DISP_BUSY Display DISP_RETURN Display DISP_RETURN Display DISP_PWR Display DISP_PWR Display 0364901 CBL, AC Power, E-series AC Line Power Entry AC Neutral Power Entry Power Grnd Power Entry Power Grnd Power Entry AC Line Switched Power Switch AC Neutral Switched Power Switch Power Grnd Power Entry AC Line Switched Power Switch AC Neutral Switched Power Switch Power Grnd Power Entry AC Line Switched Power Switch AC Neutral Switched Power Switch Power Grnd Power Entry 03829 CBL, DC power to motherboard, E-series DGND Relay Board +5V Relay Board AGND Relay Board +15V Relay Board AGND Relay Board -15V Relay Board +12V RET Relay Board +12V Relay Board Chassis Gnd Relay Board 04105 CBL, Keyboard to Motherboard Kbd Interupt Keyboard DGND Keyboard SDA Keyboard SCL Keyboard Shld Keyboard 041760000 CBL, DC POWER, EOS, "E" SERIES DGND Relay Board +5V Relay Board +15V Relay Board AGND Relay Board -15V Relay Board +12V RET Relay Board +12V Relay Board 042110000 CBL, MTHBD TO CPU,(04069, CP26)(KB) RXD(0) CPU RTS(0) CPU TXD(0) CPU CTS(0) CPU GND(0) CPU RXD(1) CPU RTS(1) CPU TXD(1) CPU CTS(1) CPU GND(1) CPU 485+ CPU 485CPU GND CPU Shield 042790100 CBL, Heater/Thermistor +12V RET Relay Board +12V Relay Board +5VANA Motherboard THERMISTOR 3 Motherboard +5VANA Motherboard THERMISTOR 2 Motherboard THERMISTOR 4 Motherboard +5VANA Motherboard +12V RET Relay Board Signal Description A Initial Release Cable Part # Revision J1 J1 J1 J1 J1 J1 J1 J1 J1 1 2 3 4 1 2 6 5 2 14 13 12 11 10 9 8 7 6 5 9 7 5 2 3 1 6 4 5 3 1 1 8 2 6 5 1 2 3 4 5 6 7 8 9 1 3 2 1 3 2 1 3 2 L N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Pin Page 1 of 2 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J12 J2 J2 J2 J2 J2 J2 J2 J106 J106 J106 J106 J106 J15 J15 J15 J15 J15 J15 J15 J15 J15 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J3 J/P DCN 4328 Signal 05827 Revision A J109 J109 J5 J5 J5 J5 J109 J109 J109 J9 J9 J9 J9 J12 J12 J12 J12 J109 J109 J4 J4 J4 J4 J4 J4 PL102 PL102 P1 P1 P1 P1 J107 P1 P1 J107 J107 J10 J10 J2 J2 J2 J2 057020400 057020400 045230100 045230100 045230100 045230100 057020400 057020400 057020400 045230100 045230100 045230100 045230100 045230100 045230100 045230100 045230100 057020400 057020400 045230100 045230100 045230100 045230100 045230100 045230100 043940000 043940000 041660100 041660100 041660100 041660100 057020400 041660100 041660100 057020400 057020400 045230100 045230100 045230100 045230100 045230100 045230100 Pump Pump Pump Relay Board Relay Board Relay Board Relay Board Relay Board Relay Board Relay Board Relay Board Bench Lamp Supply Bench Lamp Supply Bench Lamp Supply Bench Lamp Supply Bench Lamp Supply Bench Lamp Supply Photo Ref Valve Photo Ref Valve O3 Valve O3 Valve Pump Pump UV Det - Bench UV Det - Bench Bench Lamp Supply Bench Lamp Supply Fan Fan Photo Press/Flo Photo Press/Flo Photo Press/Flo Photo Press/Flo Photo Press/Flo Keyboard Keyboard Keyboard Keyboard IZ Det IZ Det IZ Det IZ Det 047020000 047020000 047020000 045230100 045230100 045230100 045230100 045230100 045230100 045230100 045230100 041660500 041660500 041660500 041660500 041660500 041660500 055220000 055220000 055220000 055220000 047020000 047020000 041200000 041200000 041200000 041200000 040010000 040010000 040030700 040030700 040030700 040030700 040030700 042580000 042580000 042580000 042580000 041200000 041200000 041200000 041200000 041440100 CONNECTION TO PN O3 Gen HTR/Therm Assembly PRINTED DOCUMENTS ARE FOR REFERENCE ONLY 1 5 2 3 1 2 1 2 3 4 6 3 4 3 5 4 3 1 2 3 4 5 6 6 12 4 6 7 8 2 3 1 3 4 1 2 1 2 4 6 5 11 1 Pin M703E Interconnect Listing J14 J/P 045230100 CONNECTION FROM Assembly PN +12V Relay Board 042800100 CBL, PWR & SIGNAL DISTRIBUTION, 703 CH1 Motherboard AGND Motherboard +15V Relay Board -15V Relay Board +12V RET Relay Board +12V Relay Board CH6 Motherboard CH4 Motherboard CH7 Motherboard AGND Relay Board +15V Relay Board DGND Relay Board VCC Relay Board DGND Relay Board VCC Relay Board +15V Relay Board -15V Relay Board CH2 Motherboard AGND Motherboard 054840000 CBL, Valve driver & pump power +12V Relay Board +12V RET Relay Board +12V Relay Board +12V RET Relay Board +12V Relay Board +12V RET Relay Board 056310100 CBL, I2C SIGNAL, 703E DGND Ethernet Board +5V Ethernet Board +15V IZS Lamp Supply AGND IZS Lamp Supply SCL IZS Lamp Supply SDA IZS Lamp Supply Shield Motherboard SCL IZS Lamp Supply SDA IZS Lamp Supply SCL Motherboard SDA Motherboard +15V Relay Board AGND Relay Board 56730000 CBL, PUMP ADAPTER, M703E 115VAC Relay Board 230VAC Relay Board Neutral Relay Board Jumper Relay Board Cable Part # 1 2 3 4 1 2 4 3 1 2 5 3 4 3 4 1 2 1 4 2 3 1 2 4 2 5 3 6 8 1 2 3 2 3 1 4 1 Pin Page 2 of 2 J2 J5 J5 J5 J5 J3 J3 J3 P1 P1 P1 P1 P1 P1 1 2 1 2 1 2 P3 P3 P3 P3 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P1 P3 P3 P3 P3 J/P 1 2 3 4 R1 SEE TABLE C1 D D 100pf -15V R6 1.0K C4 0.1uf U1 R2 R3 1.0K R4 5K 5 -15V 4 1 PHOTOCELL D1 6 3 TP1 TEST_PLUG R5 100 2 1.0K VR1 5K J1 PHOTO_OUT OPA124 C3 1.0uF +15V -15V + 7 C7 N.P. +15V VCC C C5 0.1uf + C2 1.0uf 1 2 3 4 5 6 7 8 C MICROFIT +15V VCC U2 VR2 LT1460S3-2.5 1 OUT 2 REF_2.5V PHOTO_OUT 3 C6 0.1uf IN GND +15V 1 2 3 4 5 6 7 8 GND VCC REF+ REFIN+ INGND GND GND GND F0 SCK SDO CS GND GND LTC2413 B 16 15 14 13 12 11 10 9 VCC C8 0.1 B PCA VERSION TABLE PCA# 04120-0000 04120-0200 R1 4.99M 2.0M The information herein is the property of API and is submitted in strictest confidence for reference only. Unauthorized use by anyone for any other purposes is prohibited. This document or any information contained in it may not be duplicated without proper authorization. A 1 2 3 APPROVALS DATE PCA, UV DETECTOR PREAMP DRAWN USA A CHECKED SIZE DRAWING NO. APPROVED LAST MOD. A REVISION 04420 B SHEET 3-Aug-2004 1 4 of 1 1 2 4 3 D D R1 30R, 50W TH1 J1 1 2 3 4 5 6 HEADER 6 THERMISTOR C C B B Rev Date Change Description Eng A 8/1/02 Initial release for PCA schematic KL The information herein is the property of API and is submitted in strictest confidence for reference only. Unauthorized use by anyone for any other purposes is prohibited. This document or any information contained in it may not be duplicated without proper authorization. A 1 2 3 APPROVALS DATE SCH, DC HEATER/THERMISTOR DRAWN A CHECKED SIZE APPROVED LAST MOD. B DRAWING NO. REVISION 04422 A SHEET 1-Aug-2002 1 4 of 1 1 2 3 4 5 6 P2 TP2 TEST_PLUG 1 2 3 4 +15V TIP126 Q1 8 P1 4.7K, 2W RP2D 4.7K TP4 TEST_PLUG C2 0.1 C4 R4 C3 + 220 100 7 D1 1N4148 D2 1N4148 IRF520 Q3 R2 R3 5.1K 5.1K 1N4148 D5 D 1N4148 D6 1N4148 1N4148 R6 330 C6 .033 TP1 TEST_PLUG 1 AD5321-RM8 RP2A 4.7K 2 6 C 7 5 4 C5 .01 +15V 3 R12 R13 R1 2.21K 14 1 C7 1.0UF 8 1 +15V 3 4 C8 0.1 1 3 SYNC OUTPUT A VREF NONINV. INPUT OUPUT B SOFT START CT DISCHARGE INV. INPUT SHUTDOWN OSC. OUTPUT RT GROUND COMP 16 VREF 2 5 R15 7 150 6 12 9 R16 3.9K C11 C12 .0047 0.1 U2 SG3525 B LM358 +15V 4 LM4040CIM3 10 U1A 2 2 C9 0.1 +15V 8 VCC 22 11 22 VR2 R14 10 +15V RP2B 4.7K 3 TP3 TEST_PLUG +15V U1B LM358 13 8 7 6 5 GND SDA SCL PD VC Vdd A0 A1 Vout RP2C 4.7K 15 U3 5 1 2 3 4 JP1 JUMPER2 B IRF520 Q2 D4 LAMP OUTPUT 6 VCC R7 3.9K C D3 .01 HEADER 4 VCC R5 VCC D T1 PE-6196 1 2 3 4 5 6 7 8 C10 0.1 C13 0.1 + C1 470 NOTE: THIS SCHEMATIC APPLIES TO THE FOLLOWING PCA'S: PCA# 04166-0000 A 1 CHANGE NOTES NOTE M400E BENCH AND IZS LAMP SUPPLY SHUNT INSTALLED IN J1 FOR BENCH SUPPLY SHUNT NOT INSTALLED IN J1 FOR IZS SUPPLY 2 3 REV. DATE CHANGE DESCRIPTION INITIAL A 8/1/02 INITIAL RELEASE KL 4 The information herein is the property of API and is submitted in strictest confidence for reference only. Unauthorized use by anyone for any other purposes is prohibited. This document or any information contained in it may not be duplicated without proper authorization. 5 APPROVALS DATE SCH, UV LAMP DRIVER, M450 A DRAWN KL CHECKED 3/4/97 SIZE B APPROVED DRAWING NO. REVISION 04421 A LAST MOD. SHEET 1-Aug-2002 1 6 of 1 1 M1 2 3 4 5 6 VCC M2 1 2 3 4 5 6 7 10uF DS3 S4 KBD_A0 KBD_A1 KBD_A2 21 2 3 1 SCL SDA 22 23 A0 A1 A2 INT P00 P01 P02 P03 P04 SCL P05 SDA P06 P07 P10 PCF8575 P11 P12 P13 P14 P15 P16 P17 M8 S3 VCC VCC S2 R2 1.0K U3A 1 4 3 2 1 C MF4 RN1 4.7K S1 C7 PRE CLK D CLR 5 6 Q Q + DS5 MAINT_SW LANG_SELCT DS6 GRN LED YEL LED RED LED LED 4 LED 5 LED 6 HORN SPR_I/O_0 RI-1000 ONLY Layout Instructions: A1 SONALERT Vss MF3 DS4 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 12 M10 220 2 3 4 5 6 MM74HC74A 300pF S9 VCC RI-1000 ONLY U4 VCC OPT. MAINT SWITCH S12 RN5 4.7K SPR_I/O_1 SDA TP3 BUSY SCL TP8 DISP_PWR DISP_RET 4.7K DISP_PWR_EN must be high for display to be powered. DISP_BUSY A VCC 6 7 8 9 10 J1 +5_DISP DISP_CN_A0 DISP_CN_A1 DISP_CN_A2 SCL SDA 1 2 3 14 15 AO A1 A2 SCL SDA SCL DISP_RET VCC JP3 1 2 3 4 SDA 5 6 7 8 9 10 DISP_RET (U1) DISP_RET SCL KYBRD_INT (U2) (U4) (U45 PCF8574 C11 C12 C10 220pF 220pF 220pF + C14 C4 100uF .1uF C17 VCC 4.7K SCL KYBRD_INT B Q1 C9 C8 220pF 220pF + C13 C2 C3 C5 C15 C16 .1uF .1uF .1uF .1uF P0 P1 P2 P3 P4 P5 P6 P7 INT 4 5 6 7 9 10 11 12 1 2 3 RN2 4.7K 1500uF VCC 1 2 3 4 SDA 5 DISP_PWR DISP_RET VCC +5_DISP +5_DISP DISP_WR DISP_BUSY 13 DISPLAY CONTROL U5 NOTES: 1. This schematic is based on the PWB PN, 03974 and applies to PCA PN, 03975 R4 1 3 5 7 9 11 13 15 +5_DISP DISPL CONTROL (DISP_CN_A0 -A1) 011 R3 TP9 2 4 6 8 10 12 14 16 4 KEYBOARD (KBD_A0 - A2) 111 KYBRD_INT INT 4 5 6 7 9 10 11 12 16 JP1 ADRS SLCTS TP5 SDA +5_DISP DISP_RET TP7 3 KYBRD INT TP4 VCC DISP_PWR JP2 I2C TERMINATION SCL 1 2 SDA DEFAULT ADDRESS SELECTS FOR I2C TO PARALLEL DECODERS: 2 4 6 8 10 12 14 16 18 +5_DISP TP2 TP6 PCF8574 Vss DISP_DA_A0 DISP_DA_A1 DISP_DA_A2 S13 SCL SDA DISPLAY DATA SPR_I/O_2 OPT. LANG. SWITCH 14 15 D G SI3443DV JP5 DISP_PWR_OVR DISP_WR DISP_BUSY DISP_PWR_EN MAINT_LED 1 2 MCP120T 1 U6 13 Vdd RST 3 MMBT3904 R20 Q2 1K 4.85V DTCT SPR_I/O_1 SPR_I/O_2 A 10uF .1uF JP4 Schematic for PCA #04258 and PCB #04257, Keyboard/Display Interface for E series DISP_RET Size Number Revision 04259 B Date: File: 1 S +5_DISP 6 5 4 Title J2 2 C J3 TO/FRM DISPLAY P0 P1 P2 P3 P4 P5 P6 P7 8 SPR_I/O_0 VCC TP1 SCL SDA MM74HC74A KBD_A0 KBD_A1 KBD_A2 DISP_CN_A0 DISP_CN_A1 DISP_CN_A2 3M-2514-6002UB GND KYBRD_INT AO A1 A2 1 MAINT_LED_V+ MAINT_LED LANG_SELCT 9 8 Q Q 2 3 4 5 6 7 8 9 10 MAINT_SW PRE CLK D CLR 1 2 3 Vss B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 T8201 1 3 5 7 9 11 13 15 17 MAINT SW MAINT SW RET MAINT LED V+ MAINT LED LANG SW LANG SW RET SPR I/O_0 SPR I/O RET SPR I/O_1 SPR I/O RET SPR I/O_2 SPR I/O RET 10 11 12 13 1 VCC J4 DISP_DA_A0 DISP_DA_A1 DISP_DA_A2 U3B 1. Minimum trace width 8 mil would like to have 10 mil traces if possible. 2. Please run traces on both and backside but where possible fill one side with GND. 3. Minimum width for +5_DISP, DISP_PWR, DISP_RET is 40 mil, except to test points. 4. Minimum width for VCC, GND, Vdd, Vss is 30 mil, except to test points 2 3 4 5 6 M9 D U2 S5 74C923 MAINT_LED_V+ RED KEYBOARD, LED & HORN 12 11 9 8 10 9 8 7 6 Vss M7 13 X1 X2 X3 X4 OE YEL VCC AVL Vss 14 1 2 3 4 5 2 + C6 .1uF RN3 GRN 16 C1 S6 DS2 Vdd M5 DS1 8 M6 19 18 17 16 15 D_A D_B D_C D_D D_E Vdd S7 Y1 Y2 Y3 Y4 Y5 OSC KBM 24 S8 10 D M4 Vdd M3 Vcc 20 VCC U1 3 4 5 a 21-Mar-2002 Sheet of N:\YHWork\M300B\keyboard\04257a\04259A.ddb Drawn By: 6 1 2 4 3 +15V D R2 1.1K S1 ASCX PRESSURE SENSOR 1 2 3 4 5 6 2 D VR2 3 C2 1.0UF 1 TP4 TP5 S1/S4_OUT S2_OUT LM4040CIZ TP3 S3_OUT TP2 10V_REF TP1 GND 3 2 1 S2 ASCX PRESSURE SENSOR C 1 2 3 4 5 6 +15V J1 6 5 4 MINIFIT6 +15V C R1 499 S3 FLOW SENSOR FM_4 1 2 3 2 +15V 1 2 3 4 B 3 C1 1.0UF 1 CN_647 X 3 S4 VR1 LM4040CIZ C3 1.0 B CON4 The information herein is the property of API and is submitted in strictest confidence for reference only. Unauthorized use by anyone for any other purposes is prohibited. This document or any information contained in it may not be duplicated without proper authorization. A 1 2 3 APPROVALS DATE SCH, PCA 04003, PRESS/FLOW, 'E' SERIES DRAWN A CHECKED SIZE APPROVED LAST MOD. B DRAWING NO. REVISION 04354 D SHEET 3-Dec-2007 1 4 of 1 A +5V 1 6 4 5 8 A18 A19 IC102:A 74AC00D IC101 +5V 74ACT138 1 2 3 A15 A16 A17 IC102:D 74AC00D 1 3 11 2 2 13 12 6 4 5 6 IC103:C 74ACT32 9 8 43 44 52 68 +5V STATUS PL101:2 PL101:16 2 16 PL101:12 12 R101 +5V R102 4.99K 4.99K IC106 MAX237 10 S C120 1uF 16V C121 1uF 16V S TXD PL101:3 DTR PL101:4 RTS PL101:5 DCD PL101:6 RI PL101:7 C1V+ RS-232 3 4 5 6 7 2 3 1 24 20 PL101:8 PL101:9 PL101:10 8 9 10 4 23 16 RESET PL101:11 11 8 TTL TO1 TO2 TO3 TO4 TO5 TI1 TI2 TI3 TI4 TI5 RI1 RI2 RI3 RO1 RO2 RO3 R103 499 R104 499 DS103 TXD DS104 RXD 27 28 29 32 66 5 22 17 30 15 59 12 61 62 55 67 +5V IC107 TL7705 +5V 7 2 3 1 C124 1uF 16V S C125 1uF 16V C126 S 100nF S SENSE VCC RESIN RESET CT RESET REF URTINT -LMSEL S 26 63 58 60 20 R105 4.99K S -UCS -LCS S R106 4.99K +5V PL102-1 -WR -RD +5V 7 6 18 19 21 GND +5V 4 14 15 S (3) RXD (4) DSR (7) CTS C129 10uF 16V PL102-2 C2V- S DB-9 PIN NUMBERS IN PARENS. (2) (6) (8) (1) 9 13 S 12 11 +5V +5V VCC C2+ C1+ X2 CLKO S 40 65 +5V C119 100nF 14 21 C123 C122 1uF 16V 1uF 16V GND (5) GND VCC X1 GND S -BHE LANDRQ ALE 2 7 11 13 15 12 14 16 17 75 31 18 41 Y101 18.432MHz C105 22pF 1 15 2 3 1 42 13 +5V IC104 C0561AD-L +5V C104 22pF 14 PL101:1 PL101:15 61 62 29 28 10 10 +5V +5V 33 34 36 49 63 64 5 8 NC S IC103:B 74ACT32 4 IC102:C 74AC00D PL101:14 PL101:13 IC105 CS8900A-CQ C118 100nF NC1 NC2 NC3 NC4 NC5 TXD1 -DTR1 -RTS1 -DCD1 -RI1 RXD1 -DSR1 -CTS1 -RES HLDA HOLD GND GND A19 A18 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0 D15 D14 D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 D0 LANINT 50 39 8 45 49 47 51 48 53 56 54 38 37 33 46 36 35 34 19 57 A19 A18 A17 A16 A15 60 59 58 54 53 52 51 50 48 47 46 45 44 43 42 41 40 39 38 37 25 10 11 23 13 16 17 22 9 24 2 3 4 5 6 7 18 19 20 21 24 25 26 27 74 73 72 71 68 67 66 65 64 35 30 31 32 9 7 IOCS1 6 MEMCS1 6 SBHE REFRESH AEN IOCHRDY C107 15pF 20.0 MHz X T A L 2 R108 10.0K 5 6 D V D D 1 D V D D 2 D V D D 3 D V D D 4 A V D D 2 A V D D 1 A V SLEEP D D TEST 3 LANLED ELCS CHIPSEL DMARQ2 DMARQ1 DMARQ0 DMACK2 DMACK1 DMACK0 CSOUT RESET LINKLED/ HC0 77 +5V R110 4K99 100 99 RES SA19 SA18 SA17 SA16 SA15 SA14 SA13 SA12 SA11 SA10 SA9 SA8 SA7 SA6 SA5 SA4 SA3 SA2 SA1 SA0 RXD- DS101 ACT, R113 499R DS102 LINK B S 1 +5V C103 100nF C128 100nF 78 93 R114 4K99 C109 100nF T101 TG43-1406N 92 1 RXD+ TXD- TXD+ SD15 SD14 SD13 SD12 SD11 SD10 SD09 SD08 SD7 SD6 SD5 SD4 SD3 SD2 SD1 SD0 DODO+ CICI+ DIDI+ D V S S 1 D V S S 1 A D V S S 2 D V S S 3 D V S S 3 A D V S S 4 A V S S 0 A V S S 1 A V S S 2 A V S S 3 A V S S 4 EECS EESK EEDATAOUT EEDATAIN 91 88 87 R116 24R3 R117 24R3 1:1 J101 16 15 3 14 3 11 2 1: 2 7 10 8 9 C110 100nF 84 6 2 6 C108 68pF 83 2 RX- RX+ TX- 1 4 5 7 8 9 10 TX+ NC1 NC2 NC3 NC4 S1 S2 3 82 81 80 +5V S 3 4 5 6 1 8 8 9 9 9 6 4 6 +5V C111 100nF S 79 +5V S +5V C112 100nF S +5V C115 100nF S +5V C113 100nF +5V C116 100nF S C114 100nF +5V C117 100nF C127 100nF R109 10.0K TELEDYNE ADVANCED POLLUTION INSTRUMENTATION INC. Title 1 2 3 THIS SCHEMATIC APPLIES TO PWB 04393 REV. A. ALL RESISTANCES IN OHMS, 1% PARTS DENOTED "S" ON SECONDARY SIDE OF PCA C 4 ETHERNET INTERFACE SCHEMATIC Size Number B Date Filename A +5V C102 100nF MT1 NOTES: R107 10.0K +5V R112 499R R115 100R INTRQ3 INTRQ2 INTRQ1 INTRQ0 S R111 4K99 76 +5V C101 100nF S MT2 BSTATUS/ HC1 8 1 2 5 5 7 0 3 5 7 0 8 +5V 2 5 6 8 9 9 9 2 6 9 5 0 5 9 8 X T A L 1 +5V +5V IOR IOW MEMR MEMW +5V 4 D Y102 C106 15pF +5V 11 9 NC +5V IC103:D 74ACT32 13 IC102:B 74AC00D C IC103:A 74ACT32 1 12 3 16 15 14 13 12 11 10 9 7 VCC Y0 Y1 Y2 Y3 Y4 G1 Y5 Y6 G2 Y7 G3 GND A B C B Rev 04395 A Drawn by Sheet 1 Thu Jul 25 2002 SLAN.S03 D of 1 1 D 2 3 Name 04524-p1.sch 4 5 6 D Name 04524-p2.sch Name 04524-p3.sch C C B B A A Title Size B Date: File: 1 2 3 Te 4 Te 5 M100E/200E/400E RELAY PCA SCHEMATIC Number 04522 16-May-2007 Sheet 0 of N:\PCBMGR\04522cc\source\04522.ddb Drawn By: 6 Revision D 0 1 2 J1 1 2 3 4 4 PIN D 3 4 5 AC_Line AC_Neutral RELAY0 VCC General Trace Width Requirements 1. Vcc (+5V) and I2C VCC should be 15 mil 2. Digitial grounds should be at least 20 mils 3. +12V and +12V return should be 30 mils 4. All AC lines (AC Line, AC Neutral, RELAY0 - 4, All signals on JP2) should be 30 mils wide, with 120 mil isolation/creepage distance around them 5. Traces between J7 - J12 should be top and bottom and at least 140 mils. 6. Traces to the test points can be as small as 10 mils. D RELAY1 RN1 330 R1 R2 2.2K 2.2K RELAY0 K1 RELAY1 1 4 3 2 1 4 3 K3 JP2 Heater Config Jumper 2 RELAY2 COMMON0 LOAD0 TS0 RELAY0 1 2 3 4 5 6 7 8 9 10 11 12 2 K2 RELAY2 I2C_Vcc 10 9 8 7 6 5 4 3 I2C_Vcc 2 1 1 JP1 1 2 3 4 5 6 7 8 HEADER 4X2 6 3 +- SLD-RLY +- 4 TS0 TS1 TS2 SLD-RLY COMMON1 LOAD1 TS1 RELAY1 A SLD-RLY +- YEL RL0 YEL RL1 D8 D9 YEL RL2 GRN VA0 GRN VA1 GRN VA2 D10 GRN VA3 IO3 IO4 F1 1 IO10 IO11 IO12 IO13 IO14 IO15 2 VCC 11 4 R5 10K 1 C4 10/16 1 J9 1 2 3 4 5 6 7 8 9 10 CON10THROUGH CON10THROUGH 1 2 3 4 5 6 7 8 9 10 J12 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 REV B 1 2 3 4 5 6 7 8 9 10 3 Te T CON10THROUGH D VALVE2 B VALVE3 + DD2 + 15V TVS C6 2000/25 find low ESR electroytic AUTH CAC DATE 10/3/02 CE MARK LINE VOLTAGE TRACE SPACING FIX RJ 5/16/07 Add alternate thermocouple connectors A Title Size B Date: File: Printed documents are uncontrolled 4 Te T VALVE1 +12RET J13 CON10THROUGH CON10THROUGH CON10THROUGH CON10THROUGH 2 22 uF 1 SPARE J11 1 SYNC DEMOD J10 1 2 3 4 5 6 7 8 9 10 1 MTHR BRD J8 10 TP1 TP2 TP3 TP4 TP5 TP6 TP7 DGND +5V AGND +15V -15V +12RT +12V 1 KEYBRD J7 1 2 3 4 5 6 7 8 9 10 VALVE0 8 PIN C16 11 2 A DC PWR IN J5 DGND 1 VCC 2 AGND 3 +15V 4 AGND 5 -15V 6 +12RET 7 +12V 8 EGND 9 CHS_GND 10 CON10THROUGH VLV_ENAB U2E + 1 + C5 10/16 1 R4 1M 2 1 D17 DL4148 MAX693 8 WTCDG OVR AK C2 0.001 J4 1 2 3 4 5 6 7 8 UDN2540B(16) 9 A JP3 1 2 HEADER 1X2 VCC U2D R6 10K VALVE_POWER U5 1 2 3 6 7 8 13 12 5 4 C3 1 6 IN 4 OUT4 IN 3 K ENABLE OUT 3 IN 2 OUT 2 IN 1 K OUT 1 GND GND GND GND JP4 1 2 3 K 16 15 14 13 12 11 10 9 16 15 14 10 9 U2C I2C_Vcc IRF7205 VBATT RESET VOUT RESET' VCC WDO' GND CD IN' BATT_ONCD OUT' LOW LINE' WDI OSC IN PFO' OSC SEL PFI DD1 6A RECTIFIER VCC 3 U4 1 2 3 4 5 6 7 8 DD4 6A RECTIFIER U2B Q1 F2 4A PTC INTERRUPTOR 4A PTC INTERRUPTOR SN74HC04 R3 20K VCC C U2A 5 B COMMON2 LOAD2 TS2 RELAY2 AC_Neutral +12V PCF8575 12 D7 1 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 P00 P01 P02 P03 P04 SCL P05 SDA P06 P07 P10 P11 P12 P13 P14 P15 P16 P17 Vss 22 23 A0 A1 A2 INT D4 KA 24 J3 1 2 3 4 5 CON5 21 2 3 1 D3 RED U1 Vdd C1 0.1 C D2 K D1 WDOG I2C_Vcc J2 16 PIN 1 2 RELAY0 3 4 5 6 7 RELAY1 8 9 10 11 12 RELAY2 13 14 15 16 5 Schem, M100E/M200E/M400E Relay PCB Number 04524 16-May-2007 Sheet 1 of N:\PCBMGR\04522cc\source\04522.ddb Drawn By: 6 Revision D 3 1 2 3 4 5 6 Aux Relay Connector AC_Line JP6 Heater Config Jumper RN2 330 D 1 2 3 4 5 6 7 8 9 10 11 12 RELAY3 COMMON3 LOAD3 TS3 RELAY3 RELAY4 TS3 TS4 9 10 8 7 6 5 4 3 2 1 RELAY3 1 K4 COMMON4 LOAD4 TS4 RELAY4 RELAY4 2 1 4 3 K5 2 AC_Neutral I2C_Vcc 3 I2C_Vcc +- 4 +- JP7 SLD-RLY SLD-RLY 5 4 3 2 1 D6 YEL D11 GRN D13 GRN D14 GRN D15 GRN D16 GRN Standard Pumps 60 Hz: 3-8 50 Hz: 2-7, 5-10 KA D12 GRN A JP7 Configuration D5 YEL RL3 VA6 VA7 TR0 TR1 IO3 IO4 IO10 IO11 IO12 10 9 8 7 6 1 2 3 4 AC_Neutral AC_Line C VCC 11 U3A 2 U6 SN74HC04 16 15 14 10 9 VLV_ENAB 9 GND GND GND GND U3D IN 4 OUT4 IN 3 K ENABLE OUT 3 IN 2 OUT 2 IN 1 K OUT 1 VCC 1 IO13 8 1 2 3 6 7 8 13 12 5 4 UDN2540B(16) U3B U3E IO14 3 4 11 10 VALVE_POWER J6 1 2 3 4 5 6 7 8 9 10 11 12 DD3 C17 + 13 15V TVS 14 Valve4 Valve5 Valve6 Valve7 22 uF B B CON14 U3C 14 VCC U3F IO15 C13 0.1 14 5 +12RET 6 12 +12V J19 1 2 MINIFIT-2 +12V J14 1 2 MINIFIT-2 7 13 VCC U2F Q2 IRL3303 12 7 13 Q4 IRL3303 A Q3 IRL3303 Use 50 mil traces +12V +12RET A J21 1 2 MINIFIT-2 Title Size B Date: File: Printed documents are uncontrolled 1 D PUMP J20 MINI-FIT 10 K C VA5 VA4 RL4 World Pumps 60Hz/100-115V: 3-8, 4-9, 2-7 50Hz/100-115V: 3-8, 4-9, 2-7, 5-10 60Hz/220-240V: 3-8, 1-6 50Hz/220-240V: 3-8, 1-6, 5-10 J18 16 PIN 1 2 RELAY3 3 4 5 6 7 RELAY4 8 9 10 11 12 13 14 15 16 2 3 Te T 4 Te T 5 Schem, M100E/M200E/M400E Relay PCB Number 04524 16-May-2007 Sheet 2 of N:\PCBMGR\04522cc\source\04522.ddb Drawn By: 6 Revision D 3 1 2 3 4 5 6 +15V U7A 2 10K OPA2277 TC1_GND 0.01 TC1_JGAINA R17 2 1M J 8 K 7 R- 5 Vin Gnd 0.1 R10 TC1_JGAINA TC1_5MVA TC1_JCOMPA TC1_KCOMPA TC1_GNDTCA TC2_JGAINA TC2_5MVA TC2_JCOMPA TC2_KCOMPA TC2_GNDTCA TC1_JGAINB TC1_5MVB TC1_JCOMPB TC1_KCOMPB TC1_GNDTCB TC2_JGAINB TC2_5MVB TC2_JCOMPB TC2_KCOMPB TC2_GNDTCB 4 LT1025 -15V R20 3M TC2_KCOMPA F6 1/8 AMP FUSE TC2_JCOMPA R18 TC2_GND U7B R24 TC2_GNDTCA F5 1/8 AMP FUSE ZR6 3V +15V 5 1M C JP5 MICROFIT-20 R9 10K TC PROGRAMMING SOCKET * GROUNDED THERMOCOUPLES ARE EXPECTED BY DEFAULT No extra connections are necessary for grounded thermocouples * FOR UNGROUNDED THERMOCOUPLES short TCX_GNDTCA to TCX_GNDTCB * FOR K THERMOCOUPLE: 1) Install CN0000156 for thermocouple connector 2) Short only TCX_KCOMPA to TCX_KCOMPB on TC Programming Plug 4) Leave TCX_JCOMPX pins of the plug unconnected * FOR J THERMOCOUPLE: 1) Install CN0000155 for thermocouple connector 2) Short TCX_JCOMPA to TCXJCOMPB on TC Programming Plug 3) Short TCX_JGAINA to TCX_JGAINB on TC Programming Plug 4) Leave TCX_KCOMPX pins of the plug unconnected * DEFAULT OUTPUT IS 10 mV PER DEG C 6 R22 1k OPA2277 C15 0.01 R26 14.3K Vin 2 K 7 TC2_KCOMPB Gnd R- R8 20K TC2_JGAINB R14 1M R28 TC2_5MVA TC2_5MVB 5K CW C14 0.1 8 TC2_JCOMPB B 0.01 TC2_GND J 4.7V C11 TC2_JGAINA U10 3 TOUT ZR4 7 6.81K 10K 3V THERMOCOUPLE CONNECTOR HAMITHERM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5K TC1_5MVB CW TC1_5MVA 3 TOUT C9 J16A - 2 + 1 TC1_JGAINB C8 R11 R16 10K J17 1 2 3 4 MICROFIT-4 +15V C ZR5 R7 20K -15V U8 B R25 14K 4 C10 0.1 ZR1 3V THERMOCOUPLE CONNECTOR HAMITHERM THERMOCOUPLE CONNECTOR OMEGA J16 - 2 + 1 ZR3 4.7V K 1 R13 F3 1/8 AMP FUSE ZR2 3V R21 1k 3 TC1_GNDTCA R15 10K 8 TC1_GND F4 1/8 AMP FUSE - D 0.1 C12 0.01 A TC1_JCOMPA R19 3M THERMOCOUPLE CONNECTOR OMEGA J15 - 2 + 1 J15A 2 + 1 6.81K KA -15V C7 R23 TC1_KCOMPA D R12 1M 5 R27 10K 4 LT1025 A A Title Size B Date: File: Printed documents are uncontrolled 1 2 3 Te 4 Te 5 Schem, M100E/M200E/M400E Relay PCB Number 04524 16-May-2007 Sheet 3 of N:\PCBMGR\04522cc\source\04522.ddb Drawn By: 6 Revision D 3 G1 G2 IOW DIGIO2 DIGIO3 DIGIO4 TEMP DACV WRDAC VFPROG CHGAIN VFREAD 0X32C TP2 ENAB2 U1 74HC688 9 Q 8 Q D1 4 3 2 1 Pins 1&2 shorted on PCA JP7 AEN IOEN RN16 47Kx8 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 11 PRE CLK D CLR A1 A2 A3 A4 A5 A6 A7 A8 2 3 4 5 6 7 8 9 5 Q 6 Q 1 2.2K, 5% VCC LED, RED, smt 1206 X3 74HC74 1.2 uF, 6.3V ceramic IOW 1 2 74HC32 U50A 1 1 4 5 6 19 INT A0 6 U50B 5 A13 I2C_DRV_RST U50C 6 CLK IACK INT A0 RESET 17 16 18 5 4 3 2 1 8 10 JP4 2 IRQ10 JP5 1 shorted - sldr side IRQ12 74HC08 U6C 74HC08 A14 12 A15 13 8 11 VCC 2 KBINT SDA 3 SCL SDA 7 8 9 11 12 13 14 15 DB0 DB1 DB2 DB3 DB4 DB5 DB6 DB7 6 IDC-HEADER IOR IOW IOR IOW VCC SCL DGND MICROFIT-8 2 10 VSS JP6 1 IDC-HEADER B WDI RESET C3 7 0.15 uF, ceramic I2C_RESET SHDN SHDN U5B 10 11 12 13 U51A 1 +12V 1 2 3 4 5 6 7 8 2 GND GND GND JP3 74AHC1GU04 2 INLINE-6 J106 INT shorted - sldr side 1 D0 D1 D2 D3 D4 D5 D6 D7 47k, 5% R5 1 2 U3 LTC699CS8 74HC08 VCC VCC 4 6 10 JP2 2 Q 74HC32 U39 1 Q 9 U50D VCC PRE CLK D CLR 20 VCC CS RD WR 5 1 2 3 4 5 6 3 4 8 GND GND OSC +5V BALE TC DACK2 IRQ3 IRQ4 IRQ5 IRQ6 IRQ7 SYSCLK REFRESH DRQ1 DACK1 DRQ3 DACK3 IOR IOW SMEMR SMEMW (KEY) +12V ENDXFR -12V DRQ2 -5V IRQ9 +5V RESETDRV GND 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 IOR IOW U5A 74HC74 9 DGND SDA VCC SCL I2C_RESET U10 PCF8584 SYSCLK 4 C J107 2.2K, 5% U51B NOT INSTALLED 4 R4 2.2K, 5% C39 R3 R38 2.2K, 5% 3 R25 U6D 3 IOEN 12 2 11 13 PRE CLK D CLR Q Q 9 8 SHDAC SHDAC 74HC74 74HC08 74HC32 R61 47k, 5% A KBINT Title Notes: IDC-HEADER Schematic for E Series Motherboard PCA 05702 1) This schematic is for PCA #05702 2) This schematic is for PCB 05701 Size Orcad B Date: File: 1 D R24 2 TP56 74HC08 VCC DS5 VCC TC1 13 1 JITO-2-DC5F-10OHM 4 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 MICROFIT-16 74HC08 A12 U8 DI6 DI4 DI2 DI0 DO6 DO4 DO2 DO0 DI7 DI5 DI3 DI1 DO7 DO5 DO3 DO1 12 1 2 3 1 HEADER3-DEFAULTED-1 JP1 2 18 17 16 15 14 13 12 11 DO0 DO1 DO2 DO3 DO4 DO5 DO6 DO7 DI0 DI1 DI2 DI3 DI4 DI5 DI6 DI7 12 13 14 15 16 17 18 19 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 74HC574 G1 G2 U4A ADDR=0x360 (DEFAULT) ADDR = 0x320 (JP1 INSTALLED) EN 74HC74 PRE CLK D CLR I2C_RESET 19 P=Q D0 D1 D2 D3 D4 D5 D6 D7 U51D J108 D1 D2 D3 D4 D5 D6 D7 D8 6 B0 B7 B1 B6 B2 B5 B3 B4 A0 A7 A1 A6 A2 A5 A3 A4 U4B 20 VCC 3 18 5 16 7 14 9 12 2 17 4 15 6 13 8 11 1 19 IOR 10 11 D0 12 13 9 8 7 6 5 4 3 2 U7 74HC541 VCC R59 47k, 5% D0 D1 D2 D3 D4 D5 D6 D7 74HC32 0X32F OC CLK 2 IDC-HEADER B 2 18 19 C38 0.15 uF, ceramic D[0..7] J101B PC104 1 VCC GND PC104CD A TP44 DIGIO1 C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 11 3 3 J102 VCC 6 1 DIGIO0 0X32D 0X32E C GND A0 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 AEN IOCHRDY D0 D1 D2 D3 D4 D5 D6 D7 IOCHECK 5 U6A 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11 Y12 Y13 Y14 Y15 1 D 32 A0 31 A1 30 A2 29 A3 28 27 A4 26 A5 25 A6 A7 24 A8 23 A9 22 A10 21 20 A11 19 A12 18 A13 17 A14 16 A15 15 14 13 12 11 AEN 10 D0 9 8 D1 7 D2 6 D3 D4 5 D5 4 D6 3 D7 2 1 A B C D 4 10 5 23 22 21 20 J101A PC104 3 1 2 3 4 6 7 8 9 U2 74HC154 1 2 1 1 2 3 4 5 Number Revision A 05703 17-Jun-2008 Sheet 1of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 RX1 TX1 RS-GND1 DS2 RX for Com1 R12 10k, 1% 4.9K, 5% 1 2 3 4 5 6 7 8 9 1 3 4 5 6 1 2 3 4 7 9 DB9M 1 2 3 4 DTE 10 TV ARRAY 11 8 7 6 5 R2 2.2K, 5%VCC R1 2.2K, 5% R13 R14 NOT INSTALLED DS4 8 7 6 5 VCC 1 NOT INSTALLED R10 NOT INSTALLED 2 TX for Com2 RX for Com2 1 LED, RED, smt 1206 1 LED, GRN, smt 1206 C SW1001 SW PUSHBUTTON-4PDT DS3 1 12 TV2 SMDA15LCC 1 2 NC RXD TXD NC GND NC RTS CTS NC 8 1 INLINE-12 J1013 DCE side of switch is side towards pin 1, 2 RX0 RTS0 TX0 CTS0 RS-GND0 RX1 RTS1 TX1 CTS1 RS-GND1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 R111 Com1 - RS232-A J12 D -15V 1 R11 4.9K, 5% LED, GRN, smt 1206 TV1 TV ARRAY SMDA15LCC 8 7 6 5 TX for Com1 1 2 LED, RED, smt 1206 2 1 2 3 4 1 2 1 8 7 6 5 DS1 2 C 1 2 3 4 RTS1 CTS1 D Com2 - RS232-B/RS485 J1010 DB9 FEMALE MT6 MT7 MT8 MT9 TP17 +12V +12VRET +15V -15V 1 1 1 1 VCC 1 MT1 MT2 MT3 MT4 MT5 TP18 B 1 1 TP16 1 TP15 1 TP14 1 TP13 MOUNTING HOLE 1 MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE MOUNTING HOLE B J15 AUX DC POWER IN +12V +12RET DGND +15V -15V AGND +5V AGND EGND CHASGND 8 7 1 4 6 3 2 5 9 10 VCC U51C 9 8 10 uF, 35V, TANTALUM + C2 10 D1 C1 + 74HC08 10 uF, 35V, TANTALUM MOLEX-10 MBRS340CT D9 D1, D9 & R35 must be within 1" of J15 MBRS340CT R35 A A NOT INSTALLED Title Schematic for E Series Motherboard PCA 05702 Size Orcad B Date: File: 1 2 3 4 5 Number Revision A 05703 17-Jun-2008 Sheet 2of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 3 4 C6 -15V +15V 0.15 uF, ceramic VREF 3 + 2 - U30 74HC574 1 11 D0 D1 D2 D3 D4 D5 D6 D7 U20C 9 8 CLK 2 3 4 5 6 7 8 9 6 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 19 18 17 16 15 14 13 12 CSDACA CSRANGE1 CSDACB CSRANGE2 4 3 2 1 TV3 TV ARRAY 8 IDC-8 2 4 6 8 - CSDACA 2 4 6 8 C4 C5 10000 pF 10000 pF TV4 TV ARRAY 1 3 5 7 1 3 5 7 1 2 3 4 5 6 7 8 9 10 DAC0 DAC1 DAC2 DAC3 C13 C19 10000 pF 10000 pF L5 L6 L7 L15 0 0G 1 1G 2 2G 3 3G D TERMBLOCK-8 FE BEAD J22 DAC3V 1 2 3 4 5 6 7 8 SMDA15LCC SMDA15LCC IDC-8 OP-AMP, PRECISION DUAL CSDACB J1020 J23 + 7 D1 D2 D3 D4 D5 D6 D7 D8 10 WRDAC 5 OC CLK 1 3 5 7 4 74HC32 0.15 uF, ceramic U29B 1 3 5 7 5 6 7 8 0.15 uF, ceramic 4 5 IOW -15V 2 4 6 8 C20 10000 pF L2 L3 L4 5 6 7 8 C53 U20B IOW 2 4 6 8 C8 TC2 6 L1 J21 4 R63 10k, 1% DACV 1 3 5 7 IDC-8 D DACV OP-AMP, PRECISION DUAL 1 1 3 5 7 C15 10000 pF 4 3 2 1 40K R15 2 4 6 8 4 3 2 1 1 2 4 6 8 DAC RANGE & OFFSET PROGRAM C7 10000 pF 10000 pF C21 FE BEAD J19 8 U29A 6 ANALOG VOLTAGE & CURRENT OUTPUTS 4 3 2 1 +15V TP21 5 ISOLATED 0-20MA OPTIONAL BOARDS 5 6 7 8 2 5 6 7 8 1 1 2 3 4 5 6 7 8 9 10 0.15 uF, ceramic MICROFIT-10 74HC32 +15V 0.15 uF, ceramic C10 4 U35A OP-AMP, PRECISION QUAD TP27 1 SHDAC 18.7K R19 4 2 1 5 10k, 1% 6 3 OP-AMP, PRECISION QUAD 16 15 10 SHDAC VCC 10 9 18.7K + - DAC1V -15V R23 10k, 1% 12 + 13 - 6 - -15V OP-AMP, PRECISION QUAD 16 B +15V VCC 0.15 uF, ceramic 10 + 9 - 8 9 R20 W3 B3 AGND3 18 20 17 DAC3V -15V TP33 +15V U36D A4 W4 B4 AGND4 8 6 5 12 + 13 - R21 10k, 1% 14 A Title Schematic for E Series Motherboard PCA 05702 11 1 OP-AMP, PRECISION QUAD U36C D8 D7 and D8 Must be located within 1" of U32 & U34 11 0.15 uF, ceramic -15V OP-AMP, PRECISION QUAD 14 MBRS340CT 4 2 1 POT, DIGITAL D7 A A3 DAC1V 4 POT, DIGITAL C11 + 18.7K 19 7 +15V -15V R18 10k, 1% DAC3 R22 U35D W2 B2 AGND2 DGND OP-AMP, PRECISION QUAD 8 TP32 +15V U36B 0.15 uF, ceramic U35C 8 6 5 DAC2V TP29 7 VCC C17 1 W4 B4 AGND4 18.7K 5 RS SHDN +15V 18 20 17 22 24 21 C16 DAC1 W3 B3 AGND3 A2 VCC C14 0.15 uF, ceramic 9 W1 B1 AGND1 CS SDI CLK SDO 7 0.15 uF, ceramic A4 D0 CLK A1 0.15 uF, ceramic -15V + 23 11 12 14 13 C12 C18 7 5 6 7 8 -15V DGND A3 VOA GND VCC VOB 11 W2 B2 AGND2 DOUT CS DIN CLK SOCKET U33 +15V U35B VCC 19 4 3 2 1 DAC, 12 BIT RS SHDN VCC CSDACB D0 CLK TP28 CS SDI CLK SDO A2 11 R17 11 B 15 10 22 24 21 1 3 U33 W1 B1 AGND1 DAC 2 4 D0 CLK 11 12 14 13 A1 DUAL DAC A2 U34 11 DAC, 12 BIT 23 4 5 6 7 8 11 SOCKET U31 U32 VOA GND VCC VOB 1 CSDACA D0 CLK DOUT CS DIN CLK R16 DAC0V 4 DAC0V - 4 - DUAL DAC A1 U31 2 1 1 4 3 2 1 OP-AMP, PRECISION QUAD + 3 + 2 C 4 1 3 U36A 11 TP26 C9 +15V 4 D[0..7] 1 C -15V OP-AMP, PRECISION QUAD MBRS340CT Size Orcad B Date: File: 2 3 4 5 Number Revision A 05703 8 17-Jun-2008 Sheet 3 of N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 2 3 4 5 6 5 10 1 +15V C RN14 100Kx8 +15V 5 10 J109 D + 7 10 uF, 35V, TANTALUM 9 8 7 6 4 3 2 1 U52 27 U53 -15V C44 13 2 3 18 14 15 16 17 VREF NC NC ENB A3 A2 A1 A0 C46 0.15 uF, ceramic VCC AN MUX VCC U55 DG444DY 3 14 11 6 1 16 9 8 S1 S2 S3 S4 IN1 IN2 IN3 IN4 2 15 10 7 12 4 5 13 D1 D2 D3 D4 VCC -VS GND +VS 1 CHGAIN IOW 1 3 2 8 0.15 uF, ceramic R49 100 19 18 17 16 15 14 13 12 10 uF, 35V, TANTALUM 10 5 C50 D4 VCC C D3 D7 C51 0.15 uF, ceramic D0 SEL60 IOW 5 D0 D1 D2 D3 D4 D5 D6 D7 74HC32 A 2 3 4 5 6 7 8 9 D1 D2 D3 D4 D5 D6 D7 D8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 19 18 17 16 15 14 13 12 R9 TP54 7 8 9 10 11 12 13 14 15 16 17 DB4 RDMBYTE DB3 GND U57 DB7 TIE TIE DB0 Xilinx CPLD TDI TMS TCK TC8 TIE TIE TIE TIE FREQ TIE TIE VCCIO GND TDO SEL60 39 38 37 36 35 34 33 32 31 30 29 B VCC C52 0.15 uF, ceramic SEL60 TP55 D1 IOR SA SB SC START VFREAD MSB MID LSB A Title Date: File: 3 5 TP57 Orcad B 2 X1 MB100H-4.8MHZ 100 Size 1 4 18 19 20 21 22 23 24 25 26 27 28 TP53 1 OE CLK TP52 1 1 11 1 6 1 4 TP51 1 U60 74HC574 TP50 D5 RDMSB TIE DB1 VCCINT IOR GND SA SB SC READ START D[0..7] U59B VCC 1 PLACE 100 OHM RESISTOR AS CLOS AS POSSIBLE TO X1 AND X2 6 5 4 3 2 1 44 43 42 41 40 1 2 3 4 6 7 8 9 D6 D2 VCC 74HC32 VFPROG C 1 TP48 R47 and R48 reduce the gain for analog inputs by 1%, so that we can read slightly above full scale, to prevent overflow of ADC reading + U59A Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 C54 X2 JITO-2-DCA5AE-4.8MHZ C49 -15V OE CLK D1 D2 D3 D4 D5 D6 D7 D8 AD652KP 4 1.2 uF, 6.3V ceramic U58 74HC574 2 3 4 5 6 7 8 9 VCC 0.15 uF, ceramic +15V TC6 D0 D1 D2 D3 D4 D5 D6 D7 10 uF, 35V, TANTALUM R46 1.1K, 5% 1 1 2 3 4 RN17 100Kx8 B + 18 17 16 15 14 C48 -15V 1 11 C45 COMP+ COMPAGND GND FOUT R48 200 VREF SHDN OP OUT OPOP+ 5VI 10VI 100 R47 VOLTAGE REF TP49 4 5 6 7 8 6 +15V U54 .022 uF, 50V VREF DACMUX VCC 1 TP1 1M, 1%, 1206 CHIP R45 3 2 1 20 19 C43 0.15 uF, ceramic 12 GND TC7 NC +VS NC REF NC -VSS U56 C47 1.2 uF, 6.3V ceramic 8 NC NC 7 NC VIN 6 VOUT NR 5 TRIM GND 1 - TP3 AGND TEMPMUX 1 +VSS R45 induces an offset in analog signal to give a 'live 0' for sensors with 0 or slightly negative output 3 1 0.15 uF, ceramic 2 OP-AMP, PRECISION 6 1 CH14 CH13 CH12 CH11 CH9 CH8 + 8VI OPT10V -VS COS CLK CH11 CH12 CH13 CH14 3 C42 9 10 11 12 13 CH7 CH8 28 OUT RDLSB DB2 DB6 TIE TIE TIE DB5 VFCLK ICLK VCCINT TIE CH6 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 IN 9 IN 10 IN 11 IN 12 IN 13 IN 14 IN 15 IN 16 4 19 20 21 22 23 24 25 26 11 10 9 8 7 6 5 4 CH1 CH2 CH3 CH4 J110 MICROFIT-12 C41 C40 0.15 uF, ceramic 0.15 uF, ceramic CH9 C 100 ANALOG INPUTS RN15 100Kx8 MICROFIT-12 1 2 3 4 5 6 7 8 9 10 11 12 R43 C55 9 8 7 6 4 3 2 1 CH7 CH6 CH4 CH3 CH2 CH1 C D 1 2 3 4 5 6 7 8 9 10 11 12 -15V +15V 4 5 Schematic for E Series Motherboard PCA 05702 Number Revision 05703 A 17-Jun-2008 Sheet 4 of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 1 2 3 4 5 6 +15V +5VANA U23 1 3 5 4 + C60 10 uF, 35V, TANTALUM LP2981IM5 D 2 D IN OUT ON/OFF NC GND BYPASS CAPS MUST BE WITHIN 1/2" OF THE REGULATOR INPUT/OUTPUT PINS C29 1 uF D[0..7] +5VANA VCC +15V XT1 U48 MAX382CWN 9 14 15 4 3 2 17 16 18 1 TEMPMUX D0 D1 D2 C SHDN OUT +VSS GND VENB A0 A1 A2 RS WR J27 THERMISTER 5 6 7 8 13 12 11 10 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 THERMISTER1 THERMISTER2 THERMISTER3 THERMISTER4 THERMISTER5 THERMISTER6 THERMISTER7 THERMISTER8 IOW 2 3 4 6 7 8 9 10 U59D TEMP THERMISTER6 THERMISTER5 12 11 1 C 74HC32 C MICROFIT-14 RN20 10Kx9, 2% 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B B +15V-15V RN18 U49 DACMUX 10K R34 C36 0.15 uF, ceramic VCC C37 2 15 10 7 12 4 5 13 D1 D2 D3 D4 VCC -VS GND +VS S1 S2 S3 S4 IN1 IN2 IN3 IN4 3 14 11 6 1 16 9 8 1 2 3 4 1 2 3 4 8 7 6 5 1Kx4 8 7 6 5 DAC0V DAC0V DAC1V DAC2V DAC3V DAC1V DAC2V DAC3V DAC0 DAC1 DAC2 DAC3 0.15 uF, ceramic DG444DY 10Kx4 RN21 A A Title Schematic for E Series Motherboard PCA 05702 Size Orcad B Date: File: 1 2 3 4 5 Number Revision A 05703 17-Jun-2008 Sheet 5of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 1 2 3 4 5 6 CONTROL INPUTS 5 10 5 10 VCC C RN3 510x8 TP7 C RN2 15Kx8 D U11 1 D 9 D0 10000 pF C D[0..7] R27 R28 R29 100 100 100 C97 R26 100 D7 8 74HC541 R31 R32 R33 100 100 100 R30 100 L23 L24 L26 C62 C59 L25 FE BEAD 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 330 pF, 50V 330 pF, 50V C102 C98 C96 1 C100 330 pF, 50V U13 PS2702-4 C C103 11 10 D6 6 7 D0 D1 D2 D3 D4 D5 D6 D7 D5 13 12 18 17 16 15 14 13 12 11 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 D4 4 5 10000 pF EXT_+5V_OUT C22 C56 C34 TERMBLOCK-10 L9 15 14 A1 A2 A3 A4 A5 A6 A7 A8 C101 C57 C23 L8 2 3 2 3 4 5 6 7 8 9 D3 L22 FE BEAD C35 EXTERNAL CONTROL IN A 16 DIGIO0 IOR C99 1 2 3 4 5 6 7 8 9 10 1 D2 L19 L20 L21 D1 J1004 1 19 G1 G2 9 8 7 6 4 3 2 1 9 8 7 6 4 3 2 1 U12 PS2702-4 330 pF, 50V Place these termination resistors at the end of each data line. Each data line should be laid out as a daisy-chain, the signal passing from one IC to the next. VCC C61 C58 10000 pF 10000 pF B 5 10 B 8 7 6 5 C RN4 15Kx8 U14 RN1 9 8 7 6 4 3 2 1 510x4 1 2 3 4 L28 L29 L30 L27 1 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 A1 A2 A3 A4 A5 A6 A7 A8 18 17 16 15 14 13 12 11 IOR DIGIO4 D0 D1 D2 D3 D4 D5 D6 D7 74HC541 L11 C66 10000 pF A EXT_+5V_OUT Title Schematic for E Series Motherboard PCA 05702 C65 C63 C64 C25 FE BEAD Size 10000 pF Orcad B Date: File: 1 Y1 Y2 Y3 Y4 Y5 Y6 Y7 Y8 1 19 D[0..7] L10 C24 A 1 2 3 4 5 6 7 8 9 10 TERMBLOCK-10 2 3 4 5 6 7 8 9 U15 PS2702-4 J1006 EXTERNAL CONTROL IN B G1 G2 2 3 4 5 Number Revision A 05703 17-Jun-2008 Sheet 6of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 1 2 3 4 5 6 5 10 VCC DIGITAL OUTPUTS C RN10 510x8 D D U22 9 8 7 6 4 3 2 1 1 PS2702-4 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 C80 C82 10000 pF TP19 SHDN SHDN 1 U6B 4 DIGIO2 IOW U24 74HC574 1 11 6 5 D0 D1 D2 D3 D4 D5 D6 D7 74HC32 2 3 4 5 6 7 8 9 C81 10000 pF OE CLK D1 D2 D3 D4 D5 D6 D7 D8 C79 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 19 18 17 16 15 14 13 12 U25 D[0..7] C 1 PS2702-4 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 L43 L44 L45 L46 FE BEAD J1017 1 2 3 4 5 6 7 8 9 10 11 12 L48 L49 L50 L47 FE BEAD C84 C86 FE BEAD C83 C TERMBLOCK-12 10000 pF L12 A STATUS OUTPUTS C85 C26 10000 pF C27 RESETTABLE FUSE, 0.3A, 60V VCC 5 10 D6 F1 L13 VCC C FE BEAD RN12 510x8 DIODE, SCHOTTKY 9 8 7 6 4 3 2 1 U26 B SHDN U27 74HC574 U20D 12 DIGIO3 IOW 1 11 11 IOW 13 74HC32 D0 D1 D2 D3 D4 D5 D6 D7 2 3 4 5 6 7 8 9 OE CLK D1 D2 D3 D4 D5 D6 D7 D8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 19 18 17 16 15 14 13 12 1 PS2702-4 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 1 U28 PS2702-4 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 EXT_+5V_OUT B C90 L52 L53 L54 B STATUS OUTPUTS C89 C87 10000 pF J1018 L51 FE BEAD 1 2 3 4 5 6 7 8 9 10 L56 L57 L58 L55 FE BEAD C28 A 10000 pF C88 L14 TERMBLOCK-10 C92 C91 1 2 3 4 5 6 7 8 RET GND C94 10000 pF C93 A 10000 pF Title Schematic for E Series Motherboard PCA 05702 Size Orcad B Date: File: 1 2 3 4 5 Number Revision A 05703 17-Jun-2008 Sheet 7of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6 1 2 3 4 6 5 5 10 VCC DIGITAL C IOW 1 11 8 10 D0 D1 D2 D3 D4 D5 D6 D7 74HC32 2 3 4 5 6 7 8 9 OE CLK D1 D2 D3 D4 D5 D6 D7 D8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 19 18 17 16 15 14 13 12 15 14 4 5 13 12 6 7 11 10 8 9 U18 D[0..7] 1 PS2702-4 16 2 3 15 14 4 5 13 12 6 7 11 10 8 9 C70 2 3 D 10000 pF C69 9 8 7 6 4 3 2 1 U17 74HC574 U59C 9 DIGIO0 PS2702-4 16 C67 D 1 C68 RN7 510x8 U16 SHDN SHDN OUTPUTS 10000 pF L32 L33 L34 L31 FE BEAD J1008 1 2 3 4 5 6 7 8 9 10 11 12 13 14 L36 L37 L38 L35 FE BEAD CO_EXT_RET C CONTROL OUTPUTS C TERMBLOCK-14 5 10 C74 C72 L59 FE BEAD VCC EXTERNAL CONNECTOR SOLDER SIDE C73 RN5 510x8 C71 C C95 10000 pF 10000 pF 10000 pF U21 74HC574 2 3 15 14 IOW 1 74HC32 B 1 11 3 2 D0 D1 D2 D3 D4 D5 D6 D7 2 3 4 5 6 7 8 9 OE CLK 4 5 13 12 D1 D2 D3 D4 D5 D6 D7 D8 Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 19 18 17 16 15 14 13 12 6 7 11 10 8 9 +12V L40 L41 L42 L39 FE BEAD 10000 pF D2 RELAY SPDT 4 1 3 K1 2 5 DIODE, SCHOTTKY C75 U20A DIGIO4 C78 SHDN B C77 PS2702-4 16 C76 U19 9 8 7 6 4 3 2 1 1 10000 pF J1009 Q1 R58 +12V 1 2 3 4 5 6 7 8 9 10 11 12 D3 RELAY SPDT 2.2K, 5% K2 SO2222 DIODE, SCHOTTKY 2 5 4 1 3 RELAY SPDT Q2 R6 K3 +12V 2 5 D4 4 1 3 2.2K, 5% SO2222 DIODE, SCHOTTKY Q3 +12V EXTERNAL REAR PANEL ALARM OUTPUTS TERMBLOCK-12 D5 RELAY SPDT K4 R7 DIODE, SCHOTTKY 2.2K, 5% SO2222 2 5 4 1 3 Q4 A A R8 Title Schematic for E Series Motherboard PCA 05702 2.2K, 5% SO2222 +12VRET Size Orcad B Date: File: 1 2 3 4 5 Number Revision A 05703 17-Jun-2008 Sheet 8of 8 N:\Pcbmgr\05701dn.E-motherboard.gen4\Source\05701a.DDB Drawn By: 6
